However, the technology is not new. For years, composites or sandwich panels have been used in civil and military aircraft manufacturing, and more recently they have been used in racing vehicles, ship building, and even specialized architecture. A typical Boeing civil airliner can be composed of up to 5-15% composite panel, although recently Boeing announced that the new 7E7 would be composed of up to 50% composite, making it ultralight and maintaining optimal durability. .

The success of composite technology in the aviation field has made it attractive to other industries looking to apply the benefits. One of the most important for the trucking profession is that core composites measure much lighter than steel and aluminum with an average weight savings of up to 40% over steel and 20% over aluminum.

At present, composite technology can be applied to body panels and accessories, front panels, floor, engine block, cargo liners, vehicle chassis, bumper beams, fuel tank supports, heat resistant parts such as manifold. intake, cooling modules and oil pan … Heavy wooden or metal decks on trailers can be replaced with sandwich panels to reduce more pounds and take advantage of additional payload and longer trailer bed life . The diversity in the materials used and in the manufacturing process allows composite panels to be modeled into flat or curved shapes that possess one of the highest strength-to-weight ratios of any structural material available on the market.

Replacing just a Class 8 sleeper box with custom-built composite panel technology can reduce overall vehicle weight by up to 850 pounds, effectively lowering gross weight and fluid resistance while increasing payload.

In addition to the lightweight composition, the soundproofing and insulation properties create a calm environment inside the bed; Corrosion resistance and overall durability are also high on the rating scale.

Panels are formed when two materials are combined to create a substance stronger than either of the two base materials on their own. The panels themselves are heated and thermally fused to the matrix or core; the matrix binds the fibers of the strongest material, called reinforcement. The reinforcement can be designed from fiberglass, aramid, and carbon, while the matrix can include polyester resins, vinyl ester resins, or epoxy resins, as well as many light fiber materials. The separation of the skins by this low-density core increases the moment of inertia of the beam or panel with very little weight gain, producing a highly efficient structure. Through the extensive use of high-strength adhesives, composite panels are precisely bonded providing superior improvements over conventional riveting or welding processes. Staying at the forefront of conventional practices allows the industry to realize tangible savings linked to lower direct costs of labor, tools and equipment, but primarily by eliminating costly rust and corrosion problems or claims.

Essentially, the strength of the composite panel depends on its overall size, the surface material used and the density of the cells inside, the thicker the core, the greater the rigidity and strength of the panel. Through careful selection of the reinforcement, matrix, and production process, manufacturers can produce industry-specific composite panels. Composites designed for heavy commercial applications, such as aircraft manufacturing, aerospace, oil exploration, and military markets, use continuous high-strength fibers, such as polyurethane foam or other dynamic materials, to ensure a rigid panel that can resist wear due to load stresses or mechanical stress. For low strength and stiffness or low stress applications such as automotive, marine and industrial parts, a matrix composed of non-continuous fibers such as paper or cardboard can be used, ensuring an optimal strength-to-weight ratio for the particular application .

By varying composition and thickness, compressive and tensile strength and resistance to deflection keep rock and debris damage to a minimum, as well as stress on loading and unloading. If damage does occur, panel replacement is relatively easy and affordable and can be repaired at most auto body repair facilities.

A generic composite panel is generally described as:

Some general benefits are:

• Lighter (but stronger) materials provide lower fuel consumption
• Can be customized for many specific applications
• Relatively fast implementation times
• The noise damping properties block ambient noise from outside to inside.
• Resistant to harmful chemicals and heat.
• Last longer
• Minimized structural noise

From a manufacturing or engineering point of view:

• When shock and impact loads are an issue, the size of the honeycomb cell can be adjusted to achieve different compressive strengths.
• Working prototypes using laminated panels and sandwich panels can be developed within 4-6 weeks after starting. Manufacturing processes are geared towards maximum efficiency and optimal implementation times.
• The insulation value (R value) can range from 2.5 to up to 6 depending on the thickness of the panels. Specific customer requirements can be achieved through the use of special honeycomb cores and liners.
• The range of materials used to make panels to specification makes it an attractive option for truck manufacturers.
• Design versatility in the bodywork and door panels, hoods, roof panels, hoods and spoilers allows for a drastic reduction in rolling resistance and fluid drag. Ongoing research and development is providing continuous advancements in composite performance and expanding the range of applications. The transportation industry is welcoming composite technology that may soon replace wood and metal as the material of choice.

Edison Reis, B.Sc. Eng.

Engineering and Quality Assurance Manager

Canadian Commercial Vehicles Corp.

www.ccvbc.com