A mass reduction effort of the electric and hybrid vehicle

Weight reduction, cost competitiveness, and elimination of the intrusion beam resulted from the redesign and fabrication using composite materials of the door outer panel and intrusion beam from a Chevrolet Impala. The basis of the redesign involved replacing these two steel parts with a single compression molding using the unique approach of simultaneously curing a sheet molding compound outside panel with a continuous glass fiber intrusion strap. A weight reduction of nearly 11 pounds per door was achieved. Additional weight savings are possible by taking advantage of the elimination of the intrusion beam to design thinner door structures. The parts consolidation approach allows the composite structure to be cost competitive with the original steel design for both the lower production car models and for the near to midterm production vehicles using current state of the art composite production techniques. The design, prototype fabrication, costing, material, properties and compression molding production requirements are discussed

Material applications in future automotive structure. Volume I: summary report. Final report.

National Highway Traffic Safety Administration, Washington, D.C.Mode of access: Internet.Author corporate affiliation: Budd Company, Technical Center, Fort Washington, Pa.Report covers the period Oct 1976-May 1979. Released Oct 1979. Contract amount - $632,137Subject code: BBSubject code: BGCSubject code: NSGSubject code: NVWSubject code: SCESubject code: WNBBSubject code: WOB*DECSubject code: WODSubject code: YC