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A technical and economic analysis of structural composite use in automotive body-in-white applications

IP.com Disclosure Number: IPCOM000128029D
Original Publication Date: 1998-Dec-31
Included in the Prior Art Database: 2005-Sep-14
Document File: 7 page(s) / 23K

Publishing Venue

Software Patent Institute

Related People

Kang, Paul J: AUTHOR [+3]

Related Documents

http://theses.mit.edu:80/Dienst/UI/2.0/Describe/0018.mit.theses/1998-213: URL

Abstract

A polymer composite body-in-white (BIW) design was analyzed to determine its competitive position in relation to the industry standard steel design, Three types of polymer composite materials were studied; glass reinforced vinyl ester composite, carbon fiber reinforced vinyl ester composite and sheet molding compound, The glass and carbon fiber reinforced composites are manufactured using the resin transfer molding process, A current steel vehicle design was chosen To study the manufacturing and assembly costs of the body-in-white designs, technical cost models were used, The analysis showed that a carbon fiber reinforced BIW is cost effective only at very low production volumes (5,000 vehicles per year), primarily due to the cost of the reinforcement material. Glass reinforced designs using the SMC and RTM processes can be competitive up to about 35,000 vehicles per year because of relatively low capital investment costs, In addition to the analysis of the complete BIW, subsystems within the design were also studied, The subsystem analysis indicates that polymer composite materials could be competitive at production volumes as high as 75,000 per year, primarily due to parts consolidation. Thesis Supervisor: Professor Joel Clark Title: Professor of Materials Engineering

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 This record is the front matter from a document that appears on a server at MIT and is used through permission from MIT. See http://theses.mit.edu:80/Dienst/UI/2.0/Describe/0018.mit.theses/1998-213 for copyright details and for the full document in image form.

A TECHNICAL AND ECONOMIC ANALYSIS OF STRUCTURAL. COMPOSITE USE IN AUTOMOTIVE BODY-IN-WHITE APPLICATIONS

by

Paul J. Kang
S.B. Materials Science and Engineering Massachusetts Institute of Technology, 1996 Submitted in partial fulfillment of the requirements for the degree of MASTER OF SCIENCE in TECHNOLOGY AND POLICY

at the Massachusetts Institute of Technology

JUNE 1998
SIGNATURE OF author: [[signature omitted]]

Department of Materials Science and Engineering

May 8, 1998

CERTIFIED BY: [[SIGNATURE OMITTED]]

Dr. Joel P, Clark

Professor of Materials Engineering Thesis Supervisor

Professor Richard de Neufville
Chairman, Technology and Policy Program ACCEPTED BY: [[SIGNATURE OMITTED]]

Dr. Linn W. Hobbs, John F. Elliott Professor of Materials

Chairman, Departmental Committee on Graduate Students

ARCHIVES MASSACHUSETTS INSTITUTE OF TECHNOLOGY LIBRARIES AUG 17 1998

Massachusetts Institute of Technology Page 1 Dec 31, 1998

Page 2 of 7

A technical and economic analysis of structural composite use in automotive body-in-white applications

A TECHNICAL AND ECONOMIC ANALYSIS OF STRUCTURAL COMPOSITE USE IN AUTOMOTIVE BODY-IN-WHITE APPLICATIONS by

Paul J. Kang

Submitted to the Department of Materials Science and Engineering and the Department of Technology and Policy on May S, 1998 in Partial Fulfillment of the Requirements for the Degrees of Master of Science in Materials Science and Engineering and Master of Science in Technology and Policy

ABSTRACT

A polymer composite body-in-white (BIW) design was analyzed to determine its competitive position in relation to the industry standard steel design, Three types of polymer composite materials were studied; glass reinforced vinyl ester composite, carbon fiber reinforced vinyl ester composite and sheet molding compound, The glass and carbon fiber reinforced composites are manufactured using the resin transfer molding process, A current steel vehicle design was chosen

To study the manufacturing and assembly costs of the body-in-white designs, technical cost models were used, The analysis showed that a carbon fiber reinforced BIW is cost effective only at very low production volumes (5,000 vehicles per year), primarily due to the cost of the reinforcement material. Glass reinforced designs using the SMC and RTM processes can be competitive up to about 35,000 vehicles per year because of relatively low capital investment costs, In addition to the analysis of the complete BIW, subsystems within the design were also studied, The subsystem analysis indicates that polymer composite materials could be competitive at production volumes as high as 75,000 per year, primarily due to parts consolidation.

Thesis Supervisor: Professor Joel Clark Title: Professor...