On The Development Of Lightweight IP Carrier

Paper #:
  • 2017-01-0502

Published:
  • 2017-03-28
Author(s):
Abstract:
The IP carrier plays a very important structural and safety role in the vehicle. Functionally, it forms the skeleton of the cockpit, providing the base architecture off which IP components are attached and function. At present, the IP carrier is commenly used steel, and is welded by more than 20 parts. Its weight is usually 8-14kg. For the reason of fuel efficiency and enviromental friendly, lightweight of the IP carrier is very necessary. Various lightweight technologies have been applied to IP carrier: Magnesium alloy part, Alluminum alloy part, Hybrid composite part, Composite material injection part. For Magnesium alloy part, the IP carrier which have the equal performance compared to steel part can be integrated to one part, therefore the production process is simplified. Weight can be reduced 40%-60% However, the magnesium injection part have high process requirement and need postreatment which will add cost obviously. These disadvantages limited the mass production. The cost advantage of alluminium part have atrracted some OEM. The alluminium part which have the equal performance with steel part can achieve 30-50% weight reduction. However, its integration is low, and there are some problems for alluminium alloy welding. For these reasons, the alluminium part is not applied extensively. It is reported that a hybrid steel / GMT composite IP carrier was developed, reduces 2-3kg while simultaneously improving performance compared with steel part. But the process had high requirement, and the weight reduction was less than other technologies. Composite material injection technology was noticed now because of its implicity. A carbon fiber reinforced composite material IP carrier was developed for EV. 45%-60% weight can be reduced. The NVH, crash and durability requirements can be satisfied. Moreover, BMW also developed the composite material injection part. Together the cost, process, and weight reduction, the alluminium alloy part is the concern of OEM now. but in the future, as the cost of composite material reduce, the composite material injection part would be mass production.
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