Innovative spraying process for CFRP automotive body panels

Comparing surface quality finish according to the spray process
This innovative spray process for CFRP automotive body panels
highlights the challenges of using the on-line spray process
to achieve Class A surfaces
it provides a new method for producing CFRP luggage covers using PCM and SMC processesCFRP components for the automotive industry, with clear engineering procedures and qualified production processes on appropriate equipment. In the composites industry, hot-press tank processes are commonly used in
to produce high-quality structural parts, but they also have drawbacks, so it is necessary to use specialized solutions to meet the industry's demand for low-cost, high-quality production processes. The new multi-material system luggage lid, developed by Hyundai Motor Group, uses two new curing technologies (PCM and carbon fiber SMC) in its mass production

.
was used in the Genesis G70 sports car, Hyundai Motor Group's new luxury sedan, which won Motor Trend's 2019 Car of the Year award. The luggage lid is significantly reduced in weight by 60%, is 6.4kg lighter than conventional steel construction and performs well. Its outer body plate uses 5 to 6 layers of one-way pre-immersion material, the inner plate uses 1.6 to 3.5mm thick carbon fiber SMC to locally enhance several positions to reduce stress concentration.
the design concept is evaluated based on finite meta numerical analysis and a series of structural tests involving repeated open/close durability, concave resistance, and long-term environmental durability.
Main Advantages
⊙ In mass production, CFRP components are sprayed online to solve the color matching problem,
⊙ achieves class A surfaces using traditional automotive spraying processes,
⊙'s low-temperature curing of 2K transparent paint reduces energy consumption during spraying,
⊙ reduces the weight of CFRP luggage lids by up to 60%, and
⊙ 5min solidified PCM pre-immersion high beat production.this innovation was made possible by the introduction of a new non-conductive primer (acrylic) and a finish for spraying CFRP automotive body panels.
subsequent tests show that after automatic blasting, only one layer of primer on the CFRP panel can be applied to eliminate the fiber texture. A thick layer of non-conductive primer can be sprayed online, by increasing the surface strength of the CFRP substrate so that it has sufficient bonding with the intermediate coating.
, the surface quality is equivalent to that of traditional steel components, depending on a combination of factors such as gloss, gloom and orange peel.
new way to produce CFRP luggage lids
this innovation has been shortlisted for the JEC 2019 Innovation Awards automotive category.
Hyundai Motor Group partners are: Korea Hyundai Steel Company, Korea Hyundai Motor Group Polymer Research Laboratory, Japan Mitsubishi Chemical Corporation and Korea SK Chemical Company.