However, the technology is not new. For years, composites or sandwich panels have been used in the manufacture of both civil and military aircraft, and more recently in racing vehicles, shipbuilding, and even specialized architecture. A typical Boeing civil aircraft may be comprised of up to 5-15% composite panels, although Boeing recently announced that the new 7E7 would be comprised of up to 50% composites, making it ultralight while maintaining optimal durability.

The success of composite technology in the field of aviation has made it attractive to other industries looking to apply the benefits. One of the most significant to the trucking profession is that core composite materials are much lighter than steel and aluminum with 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, heat-resistant parts like intake manifold, cooling modules and oil pan… Heavy wood or metal decks on trailers can be replaced with sandwich panels to further reduce pounds and take advantage of the additional payload and extend the life of the trailer cover. The diversity in the materials used and in the manufacturing process allows composite panels to be formed 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 one Class 8 sleeper box with custom-built composite panel technology can reduce overall vehicle weight by up to 850 pounds, effectively reducing gross weight and fluid resistance while increasing payload.

In addition to the lightweight composition, the sound insulation and damping properties create a calm environment inside the sleeper; Corrosion resistance and overall durability also rank high on the rating scale.

Panels are formed when two materials are combined to create a substance stronger than either base material alone. The panels themselves are heated and thermofused to the matrix or core; the matrix binds the fibers of the stronger material, called reinforcement. The reinforcement can be designed from fiberglass, aramid, and carbon, while the matrix can comprise polyester resins, vinyl ester resins, or epoxy resins, as well as many lightweight 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, the composite panels are joined with precision providing superior improvements over conventional welding or riveting processes. Staying ahead of conventional practices allows the industry to realize tangible savings linked to lower direct labor, tool and equipment costs, but primarily eliminates costly rust and corrosion issues or claims.

Essentially, the strength of the composite panel depends on its overall size, the surface material used, and the density of the cells within it; the thicker the core, the greater the stiffness and strength of the panel. Through careful selection of 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 high-strength continuous fibers such as polyurethane foam or other dynamic materials to ensure a rigid panel that can withstand wear and tear. 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 board can be used, ensuring an optimal strength-to-weight ratio for the particular application.

By varying the composition and thickness, the compressive and tensile strengths and resistance to deflection minimize damage from rocks and debris, as well as stress during 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 usually 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
• Noise dampening properties block ambient noise from outside from 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 forces.
• Working prototypes using laminated panels and sandwich panels can be developed within 4-6 weeks of startup. The manufacturing processes are oriented to maximum efficiency and optimal execution times
• The insulation value (R value) can vary from 2.5 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 manufacture panels to specifications makes it an attractive option for truck manufacturers.
• The versatility of the design in the body and door panels, hood, roof panels, bonnets and spoilers allow for a drastic reduction in rolling resistance and fluid drag. Ongoing research and development provides continual advances in compound performance and broadens 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 Vehicle Corporation.

www.ccvbc.com