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.

• Supplemental Notes:
  • Sponsored by NASA Prepared for JPL.
• Corporate Authors:

  Budd Company

  Technical Center, 300 Commerce Drive
  Fort Washington, PA  United States  19034

  National Aeronautics and Space Administration

  600 Independence Avenue, SW
  Washington, DC  United States  20546
• Authors:
  • Freeman, R B
  • Jahnle, H A
• Publication Date: 1980-3

Media Info

• Pagination: 193 p.

Subject/Index Terms

• TRT Terms: Beams; Composite materials; Composite structures; Cost control; Costs; Doors; Electric vehicles; Glass fibers; Hybrid automobiles; Hybrid vehicles; Panels; Weight
• Uncontrolled Terms: Cost reduction
• Old TRIS Terms: Beams (Support); Pressing forming; Weight reduction
• Subject Areas: Energy; Finance; Highways; Vehicles and Equipment; I91: Vehicle Design and Safety;

Filing Info

• Accession Number: 00326554
• Record Type: Publication
• Source Agency: National Technical Information Service
• Report/Paper Numbers: NASA-CR-163520 Final Rpt., TCR-0513
• Contract Numbers: JPL-955283
• Files: TRIS
• Created Date: Feb 18 1981 12:00AM