Future Mobility Requires Advanced Car Concepts and Power Train

Abstract

Research and/or Engineering Questions/Objective Mobility is essential for well performing economy. One Billion vehicles are on the road globally. In 20 years the fleet is estimated to double. Global crude oil demand and prices are growing. To secure economy by well performing mobility there are only two main routes to go. (1) Broader range of different power train. (2) Energy Efficiency Measures. Besides power train efficiency the curb weight reduction is an effective solution applicable for all energy and vehicle types. In 2007 Evonik Industries started to evaluate a variety of polymers and material concepts for different automotive applications. The variety of polymers, reinforcement fibres, core materials and processes represent a huge number of potential solutions competing with established materials. On the other hand this complexity is an excellent opportunities for cost effective parts. Applying new composite material technologies also offer new design options such as large and complex body parts manufactured in “one shot”. Methodology All existing and coming up material concepts, different production processes of those and different applications for automotive serial application were studied. The Target was to find out the best combination relating cost, performance and weight reduction potential. The material concepts were proofed under severe conditions on the race track and in parallel with a road approved car. Results The factors weight reduction, performance, costs and annual production volume of lightweight parts were evaluated in detail to meet automotive targets. In this process Sandwich Composite Bodywork and Polymer Glazing were identified as promising future applications of novel material concepts. For automotive application new efficient processes have to be developed with adjusted chemistry to meet automotive quality and serial volume capability. Limitations of This Study Evonik is supporting the new process technology developments for the new material concepts in co-operations. The developments are highly confidential and cannot be disclosed. What does the Paper Offer That is New in the Field in Comparison to Other Works of the Author The paper includes the potential of polymer lightweight material concepts and the gaps to be closed to succeed for automotive serial application. The paper shows very promising routes and also the very fast testing of those routes at demonstration cars. Conclusion To demonstrate the feasibility two sport cars were built with Evonik material concepts. Features are light weight body, polymer screens, friction reduced engine oil, low weight and rolling resistant tires and additional measures. This electric powered demonstration car achieves a better balance of performance, range and cost by development and application of new material concepts. In comparison to the Tesla the Evonik E-Elise is 255 kg lighter and has 3/5 of battery capacity.

F2012-E09-025