Interfaces, Cracks and Toughness : City Cars Made from Composites
- Submitting institution
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Coventry University
- Unit of assessment
- 32 - Art and Design: History, Practice and Theory
- Output identifier
- 24569327
- Type
- C - Chapter in book
- DOI
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10.1007/978-3-319-46120-5_22
- Book title
- The Structural Integrity of Carbon Fiber Composites : Fifty Years of Progress and Achievement of the Science, Development, and Applications
- Publisher
- Springer Verlag
- ISBN
- 978-3-319-46118-2
- Open access status
- -
- Month of publication
- November
- Year of publication
- 2016
- URL
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- Supplementary information
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- Request cross-referral to
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- Output has been delayed by COVID-19
- No
- COVID-19 affected output statement
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- Forensic science
- No
- Criminology
- No
- Interdisciplinary
- Yes
- Number of additional authors
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1
- Research group(s)
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- Proposed double-weighted
- No
- Reserve for an output with double weighting
- No
- Additional information
- This chapter considers the use of carbon fibre composites (CF) in hydrogen fuel cell city cars to cut emissions and improve efficiency. The chapter outlines the background to composites and assesses two causes of crack resistance that should be considered in composite car components. A series of experiments are described, and conditions to inhibit cracks identified. This knowledge has been applied to the development of Microcab. Jostins designed the H2EV model (REF2014) based on a bonded aluminium chassis with a double-skinned composite structural top body, permanently bolted and bonded to the chassis, and then fitted with single-skinned glass fibre/polymer composite body panels and doors. Carbon composite construction enables the carrying of compressed hydrogen gas in a low weight structure.
The model was further developed through the SWARM project. Jostin’s new design ‘HyLITE’ (renamed Vianova) was released in 2016. This single-seat city vehicle employs CR composites and is of lower weight than H2EV. It was built as a Left-Hand Drive vehicle to address the market in Germany where extensive hydrogen infrastructure exists, but few cars are operating.
An eight-vehicle Microcab fleet was constructed and deployed through trials outlined in the chapter. HyLITE/Vianova vehicles were shown to be amongst the most efficient hydrogen vehicles in the world. A significant reduction in drive-cycle energy is achieved through use of carbon fibre-reinforced plastic alongside a hydrogen fuel cell battery. The authors outline how it should be possible to produce a full mechanical design of integrated body, chassis, and other composite parts. The city car platform and its lean weight engineering has been adopted by German Tier 1 company Mahle. The underlying research has been widely disseminated e.g. World Hydrogen Leaders, European Electric Vehicle Congress, and at public and industry events.
Microcab was first submitted to RAE2008. The design of the second generation ‘Microcab H2EV’ was submitted to REF2014 alongside a paper outlining the development. This chapter published online in 2016, and in print in 2017 emerged through extensive testing of the Microcab fleet, and development of the third generation HyLITE’ (renamed Vianova) Microcab. The development and testing was undertaken as part of the ‘Demonstration of Small 4-Wheel fuel cell passenger vehicle Applications in Regional and Municipal transport’ (SWARM) project, funded by the EU-FP7: Joint Technology Initiatives and Fuel Cells and Hydrogen 2 Joint Undertaking (Grant Agreement 30348; 2012-2018).
- Author contribution statement
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- Non-English
- No
- English abstract
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