In collaboration with industry partners, Hexion is continually refining its resin portfolio in response to manufacturers’ increasing interest in composites as lighter weight alternatives to metal. These two new applications represent advances in resin technology that can help manufacturers reduce vehicle weight and accelerate production of high-performance Automotive components.
The new composite coil spring—an industry first—was developed in cooperation with Sogefi for Audi. The spring is manufactured using a confidential EpikoteTM Epoxy Resin / EpikureTM Curing Agent composition, which was specifically designed to meet demanding customer performance requirements while allowing mass production. The composite suspension spring is patented by Sogefi, and has been in commercial production for the new Audi A6 Avant 2.0 TDI ultra (140kW) since late 2014. Compared with traditional technology, this novel composite spring trims 4.4 kilograms from the A6 Avant 2.0, affording lower fuel consumption. It is also designed to improve driving precision and comfort.
Hexion’s second featured composite part, a Bakelite® engineering thermoset cam carrier, was developed with Ford Motor Company and Michigan-based WGS Global Services. As part of the multi-material lightweight vehicle (MMLV) program supported by the U.S. Department of Energy project DE-EE0005574, Ford is evaluating a special, lighter weight carbon fiber version of Hexion’s Bakelite® PF 1110. The material has the potential to replace cast aluminum for the cam carrier on its 1.0L I3 EcoBoost® engine. This injection-moldable engineering thermoset material is capable of maintaining its dimensional properties at operating temperatures above 200°C , and provides multiple other performance benefits
According to Hexion’s Automotive segment leader, Francis Defoor, “the Bakelite® thermoset version of the cam carrier is 30% lighter, reduces noise transmission and is expected to eliminate several costly manufacturing steps associated with its aluminum counterpart. We’re excited to be working with Ford on this innovation.”
Examples of both of these Automotive composite parts will be on display at the Hexion booth—Pavilion 7.3, Booth M18—during the JEC Europe 2015 composites show, Paris Expo Porte de Versailles, March 10-12.
An engine containing the carbon-fiber reinforced composite cam carrier can also be seen at the Ford display at the Society of Automotive Engineers (SAE) World Congress in Detroit, April 21-23.