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A Study on mPPO Development and Injection Molding Process for Lightweight Stack Enclosure of FCEV
Soo-Lim Lee1, Jong-Hwal Kim2, Seon-Bong Lee3
1Department of Mechanical Engineering, Keimyung University, Daegu 42601, Republic of Korea.
Polymers
|March 11, 2023
Summary
This study developed modified Polyphenylene Oxide (mPPO) for lightweight fuel cell electric vehicle (FCEV) stack enclosures. The research optimized injection molding processes, reducing cycle time and enhancing mechanical strength for cost-effective, eco-friendly automotive manufacturing.
Area of Science:
- Materials Science
- Automotive Engineering
- Manufacturing Processes
Background:
- The automotive industry is pursuing carbon neutrality (Netzero) through eco-friendly vehicles.
- Lightweighting vehicle components, such as stack enclosures for Fuel Cell Electric Vehicles (FCEVs), is crucial for improving fuel efficiency.
- Modified Polyphenylene Oxide (mPPO) is a potential replacement for aluminum in automotive applications, requiring development for injection molding.
Purpose of the Study:
- To develop mPPO suitable for injection molding of FCEV stack enclosures.
- To predict and optimize the injection molding process for stack enclosure production.
- To verify the proposed process conditions through mechanical stiffness analysis.
Main Methods:
- Development of mPPO material.
- Physical property testing of mPPO.
- Prediction of injection molding process flow using simulation.
- Proposal and verification of injection molding process conditions.
- Mechanical stiffness analysis of the molded component.
Main Results:
- Optimized runner system design with pin-point and tab gates.
- Proposed injection molding conditions achieving a cycle time of 107.627 seconds and reduced weld lines.
- Mechanical strength analysis confirmed the component can withstand a load of 5933 kg.
Conclusions:
- The developed mPPO and optimized injection molding process enable weight and material cost reduction compared to aluminum.
- The proposed manufacturing approach enhances productivity and reduces production costs for FCEV components.
- This advancement supports the automotive industry's goals for sustainable and efficient vehicle production.
