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QarmaQ challenges convention
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01/04/2007
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Roger Bishop reports on how an automotive OEM and a major plastics supplier have cooperated on a fully engineered concept crossover utility vehicle packed with advanced systems for future platforms
Back in the 1980s and early 1990s when new polymer types were exploding onto the market almost on a monthly basis, the plastics industry faced a severe communications test. How to convince the automotive sector – its biggest potential customer – that these materials could benefit future vehicle systems in terms of cost, weight, styling and unique properties.
Since those days, the application of plastics within the automotive sector has, of course, been explosive and hugely successful. Yet within vehicle OEMs and some Tier One suppliers – bar the specialists – it is generally accepted that the level of expertise in plastics systems is still not all that it should be.
Back in those ‘pioneering’ days, GE Plastics led the industry in recognising the benefits of presenting new materials to the industry by solving the problems of applying plastics up-front with fully engineered and tested systems and vehicle concepts. Now, working with Hyundai’s Design and Technical Centre in Russelsheim, Germany, GE engineers at Bergen op Zoom in the Netherlands have carried that original thinking through to a 21st century concept crossover coupé, the QarmaQ advanced technology demonstration vehicle.
The developments feature leading edge materials including Xenoy iQ (for the highly innovative Elastic Front safety systems) and Valox iQ (for under-the-bonnet components) that have been created with polybutylene terephthalate (PBT)-based polymers derived from 85% post-consumer plastic waste. They consume less energy and create less CO2 in their manufacturing than traditional resins. Manufacture of the single QarmaQ prototype helped divert around 900 PET (polyethylene terephthalate) bottles from potential landfill.
QarmaQ features some 30 advanced technologies in five key areas: the front end, exterior, interior, lighting systems and under-bonnet systems. Fuel savings of up to 80 litres/year are demonstrated along with improved pedestrian safety and the ability to create complex, 3D shapes. They will be selectively incorporated into new Hyundai’s models to be rolled out between 2008 and 2014.
The Elastic Front is designed to reduce the risk of severe injuries to pedestrians. The bonnet has already met standard industry tests and simulation has shown that the front-end will do the same. Included is a single design for energy-absorbing countermeasures for lower leg protection that meet FMVSS/CMVSS and European and Japanese pedestrian Phases I and II requirements. Using a new resin technology the part combines two functions – it is soft and supple enough to absorb energy when contacted by the lower leg of a pedestrian but stiff enough to meet specifications for low speed impacts with solid objects.
Due to the higher bonnet position of a CUV, absorbing energy in the area around the junction of the top of the grille/bumper and front of the hood is critical as this will potentially impact a pedestrian’s hip area. The physical properties (modulus and ductility) of the latest Xenoy iQ HMD (high modulus ductile) resins make this possible without additional complex structures or mechanical solutions.
Head injury reduction is influenced by both front fender and bonnet design. The lightweight bonnet provides energy absorption through its design and the crash management properties of the HPPC thermoplastic composite technology (based on Xenoy) used as replacements for ductile metal structures. The large injection-moulded, vertical wraparound fenders made from HMD resins form part of the horizontal hood surface and must therefore also be capable of meeting head impact requirements. According to GE, HMD technology allows large automotive mouldings to be implemented while meeting OEM requirements for dimensional tolerance on gaps and flushness. A technique known as nanotechnology fibrillation is said to be key to improving the dimensional stiffness of large body panel components.
Exterior systems include movable side glazing based on Exatec 900 polycarbonate GE’s joint venture with Bayer MaterialScience. Seals are integrated using a two-component moulding process and the material is given glass-like abrasion resistance using a proprietary coating applied using PECVD (plasma-enhanced chemical vapour deposition).
A polycarbonate (PC) panoramic sunroof module with UV-blocking technology provides everything from lighting to telemetry. Manufactured with a multi-band Fractal Antenna from Exatec and the Spanish Tier One supplier Ficosa, the module integrates antennas and could also use Exatec’s electroluminescent interior light band for an improved interior ambiance.
Dramatically sculpted doors are up to 50% lighter compared with metals, again using iQ resins. And the lift gate has been designed as a fully working sub-assembly with the rear lighting, wiring, sensors and electronics integrated into component. It meets the regulatory requirements for driver visibility as well as enabling the use of a wiper and defroster technology from Exatec.
Mirror de-misting and defrosting is monitored and controlled using GE’s sensing technology and a new thermoelectrically conductive material from GE Plastics called Statkon. The material is made by compounding base polymers with electrically conductive fillers or reinforcing agents such as carbon powder, carbon fibre or steel fibres producing conductive and dissipative materials in the 100 to 1012 ohms/sq resistivity range.
Inside QarmaQ plastics figure strongly, too. Displays and LCD backlit instrumentation use Illuminex polycarbonate coating-free diffuser technology. Doors are trimmed with back-moulded using Cycoloy PC/ABS which allows the fabric to be processed without stretching or damage. Visualfx special effects colour compound has been used with polycarbonate for the instrument cluster, dashboard, vents switches and door trim. Another grade of polycarbonate – EXL – enabled the airbag door to be seamlessly integrated into the fabric-covered instrument panel and is a candidate for designs with airbags behind the pillar trim. Seat backs and centre console are designed in a deep gloss ‘Ceramic’ while anti-static Geloy XTW resin as a capping stock (compatible with ABS and PVC) for its prolonged delay in aesthetic shift and UV resistance.
The lighting system has front lenses moulded in polycarbonate and the headlamps saw the debut of Nightfx, water-clear materials that glow in brilliant colours when exposed to certain wavelengths of light. The headlamp bezel is a directly metallised Valox iQ resin while reflectors moulded from GE’s new direct-metallised Extem brand which covers both amorphous thermoplastic polyimide (TPI) and polyetherimide (PEI) resins. What they have in common is outstanding heat resistance (up to 311ºC), high strength, stiffness and creep resistance.
Under the bonnet, Valox iQ resins have been used for connectors while Noryl PPO (modified polyphenylene oxide) allows thinner coatings on wiring, significantly reducing the bundle size.
QarmaQ’s safety structures, glazing, interior and exterior systems have all been engineered using advanced polymer technologies
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Author
Roger Bishop
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