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EconCore热塑性蜂窝芯满足运输轻量化挑战需求  发帖心情 Post By:2018-07-15 16:07:00 [只看该作者]


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EconCore’s Thermoplastic Honeycomb Core Meets Transportation Lightening Challenges

Published on 2018-07-09.  

EconCore has established a reputation as one of the leaders in thermoplastic honeycomb core materials and technology. Connecting the steps of first making the honeycomb core with in-line bonding of skins to make lightweight and stiff sandwich panels has enabled EconCore to license its ThermHex process to companies around the world operating in various market sectors. 

  • The key is the technology’s versatility of materials, combined with a high-speed, continuous, cost-efficient production process. 
  • EconCore’s ThermHex process allows users to provide performance-to-weight-optimized materials with a honeycomb structure to higher-volume applications than previously possible. 
  • Instead of being limited to low-volume and less cost-sensitive domains, EconCore brings honeycomb structure to mass markets.

Continuous, high-speed in-line production=
Continuous, high-speed in-line production of honeycomb materials for transportation applications

Honeycomb Core Materials for Lightening


With the versatility to combine different core and skin materials using EconCore’s continuous, cost-efficient process technology, honeycomb core materials are finding their way into an increasing range of transportation applications. 
  • Lightweighting can lead to economic rewards and reduced environmental impact. 
    • For truck trailers and truck bodies, for example, the potential for weight reduction is compelling with honeycomb core materials being up to 90 percent lighter than incumbent solid cores. 
    • For fleet operators looking to reduce fuel consumption to increase cargo capacity and minimize environmental impact, the benefits are clear. 
  • Lightweighting is valuable: for a full-size trailer fuel consumption savings of 6-8 percent is achieved per 10 percent reduction in trailer weight. 
  • Lightweighting with innovative honeycomb materials is already happening and is growing rapidly. 
  • Leaders in commercial transportation in North America and Europe are adopting EconCore’s ThermHex technology and offering innovative product solutions to meet the challenges in commercial transportation and delight their customers.

Metal Skins


The ability to combine thermoplastic honeycomb core materials with metal skins using the in-line, continuous ThermHex process has attracted the interest and investment of leading innovative companies in both Europe and North America. 
  • Leading the way in the U.K. is Tata Steel, producing Coretinium? using EconCore technology which combines in-situ produced polypropylene honeycomb cores with their Colorcoat Prisma? pre-finished steel skins. This breakthrough in rigidity-to-weight performance is delivering substantial value to Tata’s commercial transportation customers. 
  • One notable example is Cartwright’s new Streetwise? Urban Delivery Trailer, deployed in U.K. cities, a half-ton lighter than before thanks to Tata Steels Coretinium composite made using EconCore technology.

High performance=
High performance at reduced weight is good for both the bottom line and the environment

Coretinium


Passenger transport is a demanding area that requires performance and compliance. 
  • Coretinium, with its fire-resistant steel skins, passes the industry standard R118-Annex 6. 
  • Coretinium is ideal for flooring in passenger transport vehicles. 
  • It is well suited for buses, particularly for the engine bay, where Coretinium is essentially a steel sandwich for the floor panel and fire wall, and provides a lightweight, stiff and fully compliant option for manufacturers.

Overall, with its unique combination of high-performance aesthetics, Coretinium is an ideal solution for reducing vehicle weight and emissions and increasing payload. 

Reinforced Thermoplastic Composite Skins


Together with its subsidiary ThermHex Waben and Fraunhofer IMWS, EconCore is putting much effort into application and process developments for the EU-funded project Organosandwich, a material made of thermoplastic honeycomb cores with composite skins reinforced with continuous glass fibers. 
  • Complementing and adding to the range of material combinations for commercial trailers, Organosandwich materials provide another means to reduce weight and improve the bottom line. 
  • Comparing, for example, a trailer made with traditional GRP laminated plywood to an Organosandwich made of a polypropylene (PP) honeycomb core with PP/GF composite skins, the Organosandwiches are more than 60 percent lighter, and for a trailer made of traditional GRP and plywood initially weighing 6.5 metric tons, the weight savings is approximately 18 percent (1.15 tons) when made with Organosandwich materials. 
  • This translates to significant fuel savings or increased cargo capacity per unit and, when scaled to even a medium-sized fleet, this is enormous.

Honeycomb core=
Honeycomb core solutions reduce fuel consumption and increase payload capacity

Consider that for a fleet manager having 100 units, with a total weight of a typical pulling tractor-trailer assembly of 13 tons and where a truck makes 100,000 km/year on average and consumes 40 liters of diesel per 100 km, such a 1.15-ton reduction may mean equal a fuel savings of roughly 250,000 liters. Over a few years, such fuel reductions would result in cost savings ranging in the millions of euros. It is up to the fleet manager to decide how to apply the value from the lightweighting – be it in fuel savings or increased payload, or a balance of both.

Organosandwich is an intrinsically stiff material and lightweight due to the low-density honeycomb core. With the drive to replace heavy parts with lighter ones and the goal to ultimately reduce CO2 emissions, Organosandwich materials are being considered for a wide range of transportation applications. These materials provide excellent rigidity and the impact-resistant properties needed for the automotive industry, and at a lower weight than traditional heavy parts. With the drive for lightweight solutions in transportation industry, the future is bright for Organosandwich materials, for fleet managers and vehicle owners, and for the environment. 


Source: EconCore


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