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Self-expanding foam core material has been successfully applied to complex automotive structural parts

 Last Update: 2022-08-22
 Source: Internet
 Author: User

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A few days ago, the Dutch auto OEM Donkervoort formally established an independent company for the application of its Ex-Core process technology

One-step molding process

The development of the Ex-Core process began by coincidence, when Donkervoort engineers discovered that the foam core they had developed could grow uncontrollably in the hot sun

After ten years of sharpening a sword, the researchers finally determined the formula of the foam core material after ten years of painstaking research, and carried out relevant tests and verifications

More complex structure and more diverse applications

Ex-Core technology includes not only the specific formulation of the foam material, but also its complete process, as well as a device specially designed for the process, so that customers can directly control the process with the equipment

The device itself is the mold of Ex-Core, and the internal pressure can shape complex shapes with great ease, which is unprecedented in the field of CFRP applications

Another advantage of Ex-Core is that there are fewer hidden defects in the part

The pressure applied to the fibers can be 2bar, 8bar and 20bar, depending on the formulation and curing profile

Ex-Core system molds are not divided into yin and yang, the operation is not complicated, and the possibility of mistakes is small

Designed for cars

The Ex-Core process system developed by Donkervoort is mainly for personal use, but the system is also suitable for yachts, sports cars, bicycles, other professional sports, and even the field of drones
.

Over the next two years, Dondervoort will scale up Ex-Core to mass production through the EU's SME2 program, and the technology will continue to expand beyond the automotive sector
.

For all possible applications outside the traditional automotive industry, the development of electric vehicles has undoubtedly created huge opportunities for the application of this technology
.
Since the battery weighs so much, weight savings elsewhere in the car is valuable
.

Additionally, Ex-Core technology reduces vehicle noise, vibration and harshness (NVH)
.
While NVH has proven to be a big problem in electric vehicles, especially with CFRP structures, products produced with Ex-Core technology are able to absorb vibrational energy more efficiently
.

At the same time, Ex-Core technology can absorb impact energy, reducing the risk of catastrophic structural failure after small collisions, and the components will also be easier to repair than the current common CFRP monocoque structure due to the presence of the foam core
.

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