Teijin Automotive innovates core technologies for body panels

Cross-section of an automotive body panel made with Hexacore core and process technology. Photo credit, all images: Teijin Automotive Technologies

Among its latest automotive composites innovations, Teijin Automotive Technologies (Auburn Hills, Mich., U.S.) has developed two core products aimed at meeting the needs of current and future automotive applications.

Jeep Wrangler Freedom panel molded with Hexacore.

Hexacore is a honeycomb core product designed for use with Teijin Automotive’s high-speed compression molding process in the manufacture of lightweight, Class A body panels, roof panels, closures and more.

In this process, a sheet of Hexacore honeycomb is placed between two dry fiber mats. A robotic gripper arm transfers the layup into the sprayup station, where both sides are sprayed with polyurethane or another resin. The layup is then moved to a compression press for molding. Fasteners and trimming can be directly molded onto the part, and the final part is completed within a 30-45-second cycle time.

Hexacore materials are compatible with a range of fibers and resins, including carbon or glass fiber, aramid fiber or natural fiber; thermoplastic resins including acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA) or polycarbonate (PC); or low-density sheet molding compound (SMC). It can also be used for other processes such as resin transfer molding (RTM) and with a variety of coatings, veils and films. The use of Hexacore materials is said to result in 25% weight savings compared to a comparable two-piece SMC part.

Cross-section of a panel made with Foam-A-Core.

In addition, Teijin Automotive developed Foam-A-Core technology as a rigid core solution for Class A automotive panels that are high strength and impervious to moisture.

Molded in the same 30-45-second compression molding process, this technology allows for molded-in features and fast cure. Like Hexacore, Foam-A-Core is compatible for panels made from a variety of fibers, thermoset or thermoplastic resins, SMC or via an RTM process. The process also produces a near-net shape part, reducing manufacturing scrap compared to other methods.

According to Teijin Automotive Technologies, both materials are currently in development and have been used on a variety of prototype applications. The company aims to launch these to the larger commercial market soon.