Abstract
Carbon fiber reinforced plastic (CFRP) materials are the future lightweight materials, being well-received in all industries, including the automotive industry, better than other lightweight materials. However, CFRP-based devices are expensive because of the raw material, carbon fiber. There are also industrial challenges, since industry still uses the existing steel-based automobile manufacturing facilities. In this chapter, we review recent trends in carbon fiber composite materials and development of carbon fiber-reinforced thermoset/thermoplastic composites in the automobile industry in terms of raw materials use and their processing methods. In particular, we introduce the CFRP manufacturing processes that the Korea Institute of Carbon Convergence Technology (KCTECH) has developed for a decade based on the molding equipment and process base of the carbon industry. KCTECH is a specialized research institute established for research and development in the Korean carbon industry, including: (1) multitow spreading machine, (2) hybrid braiding machine, (3) manufacturing system of thermoplastic carbon prepreg with multifunction, (4) automated fiber placement machine, (5) carbon fiber preform (tape) manufacturing system, (6) high-pressure resin transfer molding system, (7) high precision compression molding press with high temperature, (8) winding machine of carbon fiber (filament winding), (9) vacuum microwaves kiln for fast CFRP curing, (10) 3D dynamic waterjet cutting system for CFRP, and (11) machining center for high-strength composite parts reinforced carbon fiber. We provide a case example of lightweight automobile parts using CFRP, such as a side impact beam, acoustic cover for a car engine, CFRP stabilizer bar for automobiles, CFRP leaf spring, CFRP roof rail, and hybrid composite pressure vessel. We further compare current CFRP-based technology with future CNT sheet and yarn technology in terms of current challenges, such as cost reduction and manufacturability. This chapter discusses recent use of various resins used in CFRP manufacturing and examines the development trends of thermoplastic materials suitable for automotive applications in CFRP products and future carbon nanotube (CNT)-based carbon fiber composite technology.
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