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1. Automotive Doors – New Technology and Trends
Emissions from road transport increased by 26% between 1990 and 2008, with
passenger cars currently responsible for 12% of overall EU emissions of CO2 (1).
The EU introduced regulations for passenger cars in 2009 with targets for emission
levels that manufacturers must adhere to. By 2015 passenger cars should have
maximum emissions of 130g CO2/km, with a further target of 95g CO2/km to be
achieved by 2020. Limits for the emissions of light commercial vehicles were added
to the legislation in 2011, stating that the maximum should be no more than 175g
CO2/km by 2017 and 147g CO2/km by 2020.
These targets for reduced emissions are one of the biggest drivers of innovation in
the automotive manufacturing sector, with weight reduction at the forefront of
development. To meet the regulations each car manufacturer is assessed on the
emissions of their overall fleet. Every new car registered is given an indicative
emission level based on its mass, and manufacturers must ensure that the average
mass of all its cars is in line with the emission allowance. Heavier cars are targeted
for greater emissions than lighter cars, so the reduction in the mass of their overall
fleet will help manufacturers to comply with the legislation.
Trends
The automotive door sector is one area in which manufacturers are looking to
reduce overall weight by using alternative materials and new manufacturing
concepts. Door suppliers are continually striving to improve the design and
engineering of their products, and any reduction in weight will need to be integrated
with other areas of innovation such as noise reduction, closure and sealing systems
and keyless technology.
Brose
The automotive supplier Brose introduces a new concept in design last year when
they introduced a door system manufactured from wood-fibre reinforced
polypropylene (2). The door structure provides a 6% weight saving against
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2. conventional door systems at no extra cost, and has several other advantageous
benefits. Wood-fibre reinforced plastic is a sustainable material which is carbon
neutral. The use of renewable and recyclable materials is another trend in the
industry, again in the pursuit of carbon emissions reduction.
Pictured below, the door system offers manufacturers protection from price
fluctuations in raw materials, such as plastics derived from crude oil. The carrier
plate is manufactured from polypropylene which has been reinforced with 40%
wood fibre. In comparison with a glass-fibre reinforced door system, the Brose
design reduces the amount of plastics used by 20%.
Source: Brose
Crash testing results showed that the door system offers the same level of safety as
a glass-fibre reinforced solution; and the integrated doors also contribute to better
thermal and acoustic insulation.
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3. Magnesium Doors
The use of magnesium for car body parts, including doors, to replace steel could be
an option for manufacturers as it offers great potential for weight saving (3).
Magnesium parts can be manufactured which provide a similar rigidity to steel, but
are up to 50% lighter. Researchers at the Die Fraunhofer Institute for Machine Tools
and Forming Technology IWU designed and produced an example door last year
which was showcased at the Hanover Messe trade fair in April. The magnesium door
weighs just 4.7kg compared with a similar steel door at around 10.7kg.
The advantage of using magnesium is that it is a resource which is available in large
quantities world-wide, it can be easily moulded during production, and it possesses
much the same properties as steel. Engineers at the Fraunhofer Institute have
developed specific moulding technologies for wrought magnesium alloys, and it is
the processes they are developing which may lead to the use of magnesium in mass
production for car parts.
Tailored Blanks
The use of optimised sheet metal parts, manufactured specifically, is another
manufacturing option which can reduce weight and offers a variety of benefits for
car makers, such as reduced cost and enhanced crash protection. One company
supplying products to the automotive industry is ThyssenKrupp (4). They produce
tailored blanks constructed from individual sheets of steel of differing thickness,
strength and coating which are joined by laser welding. By tailor-making the
products, ThyssenKrupp ensure that the completed part has the right grade of steel
in the right place.
The tailored parts reduce the need for reinforcement and overlapping joints within
the part, so require less material which reduces weight. The targeted use of steel
with different properties also helps to lower cost as well as weight. The more
expensive materials are used only when necessary, while cheaper grades of steel
can be used in non-essential areas. The structural strength of the vehicle and the
crash performance can also be improved through the use of tailored blanks for
doors. The thicker, high strength steels are used in areas of high tension and areas
which may suffer the impact in a crash.
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4. Mercedes-Benz F125!
Source: Daimler Technicity
One highly innovative design for a door system is the Mercedes-Benz F125! Concept
vehicle, pictured above. Engineers designed the car with a view to vehicles in two
generations time, and have developed several visionary features, not least the gull
wing doors. The research car has been built so that designers can study the future
for automobiles and obtain new knowledge about how different innovations work in
practice.
The doors are of a light weight and high strength CRP construction, while crash
protective systems built into the door allow the removal of the B pillar. The doors
allow access to all four seats of the vehicle at the same time, and can be controlled
from the front or rear seats of the car. Opening and closing of the doors is
completely contact-free from the outside, as simple wiping gestures can control all
of the functions, with a control element built into the rear side window. The doors
can be opened or closed from within the car by the simple touch of a button, while
outside, it is possible to use a smartphone to unlock and open the doors.
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5. The F125! Is a design inspired by the thought of what the car may evolve into by
the year 2025, and gives an insight into one way in which the automotive door may
develop.
Fibre Reinforced Plastic
Fibre-reinforced plastics are becoming more and more commonplace in car
manufacturing as the trend towards weight reduction continues. Electric cars in
particular will benefit from the use of lighter materials due to the weight of the
heavy battery packs that they have to carry. Market research firm Lucintel (5),
revised its prediction for the growth of the carbon-fibre plastics market in its most
recent market report, “Growth Opportunities in the Carbon-Fibre Market 2010-
2015”. They estimated that the market could grow by 13% per year over the five
year period. Automotive manufacturing is sure to contribute to the growth in the
sector, and research is ongoing amongst manufacturers to develop more and more
parts and components from composite plastics.
Summary
The EU requirements for carbon emissions from passenger vehicles is pushing
manufacturers into developing newer and innovative technologies which can reduce
weight and contribute towards the targets. Door manufacturers have several other
demands from consumers which are also being developed alongside weight
reduction initiatives. Consumers and therefore car makers, demand more
technology in the door, as well as greater safety and security, and enhanced noise
reduction for greater comfort.
The challenge for door manufacturers is to integrate all of these requirements into
door systems which also save weight. The Brose development of a wood-fibre
polypropylene door system is one example of the types of door structures that could
soon be in serial production. The doors offer weight saving compared to steel door
systems, and provide extra thermal and acoustic insulation. The use of a
sustainable material such as wood-fibre has several advantages and is likely to be a
continuing trend in the coming years. Using renewable materials helps towards the
EU’s overall carbon emission targets, and lessens the reliance on fluctuating
material prices due to crude oil prices.
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IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany
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6. Magnesium doors are another trend which is likely to undergo rapid development in
the industry, as they offer substantial weight savings of up to 50% compared with
steel doors. Techniques being developed at the Fraunhofer Institute can produce
materials which have similar strength and rigidity to steel, and the processes they
are developing could see magnesium being put to use in mass production in the
automotive industry over the next few years.
The Mercedes-Benz F125! Research vehicle offers a glimpse into the future of auto
manufacturing, with a car designed with the 2025 and the evolvement of the
passenger car in mind. The gull wing concept completely removes the B pillar, and
the door is constructed from a light weight CRP material. Several technologies have
been integrated into the door with touch button controls and contact-free opening
from the outside via a smartphone.
Ultimately, manufacturers must develop designs in the future which can meet the
demand for lighter doors, with better crash protection, enhanced acoustic
performance, and integrated technology.
Colin Pawsey
Colin Pawsey’s background and experience is in the water heating industry, with a focus on
technical data analysis and energy efficient products for both commercial and residential
sectors. He also works as a freelance journalist focussing on renewable and sustainable
resources, energy efficiency, and consumer information.
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IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany
t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de
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7. References:
(1) http://ec.europa.eu/clima/policies/transport/vehicles/cars/faq_en.htm
(2) http://www.brose.de/ww/en/pub/press/content12499.htm
(3) http://www.fraunhofer.de/en/press/research-news/2011/april/resource-
friendly-car-manufacturing.html
(4) http://www.tailored-blanks.com/en/products/tailored-products/thyssenkrupp-
tailored-blanks.html
(5) http://www.lucintel.com/
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