Prius body panels..why not make them out of composite

fuelsipper · 07-10-2006, 05:45 PM

material. I do not know the technical term, but am thinking plastic/kevlar, or some concoction thereof. Maybe that would be too expensive to make. And I just might find out...
The point is...the body on the Prius is about as sturdy as a can of Hamms Beer (not that I would know how that tastes)
I could go on with all of the body damage our 2005 Prius has aquired, most in parking lots (yes, we always look for a good spot, it still happens)

I am wishing for a plastic body, one that pops back into shape. Way past the first dent phase, just wondering if anyone else has had a thought on the subject..

E-Eric

Godiva · 07-10-2006, 05:51 PM

The side panels on my 1996 Saturn SC2 coupe were some sort of plastic. You could pound on them and they would give and bounce back. It was a selling point and after 10 years it didn't have any "dings". I imagine they would make the car lighter. You would need to reformulate the paint so it would be flexible like the panels. The frame was a cage to protect the passengers, much like the Prius.

jtullos · 07-10-2006, 06:10 PM

At present, making composites is neither easy nor cheap. I've done a very small amount of work with composites, and yes, they are lighter and stronger. However, composite production is not yet (to my knowledge) fully automated, certainly not on the scale necessary for a production automobile.

Composites are not necessarily flexible. Some are, some aren't. It's all in how the composite is put together. What I worked with, and those I've seen, are all for rigid applications (airplane wings, rocket/satellite components, etc). These are all applications where a few pounds can make a huge difference in cost. Launches to orbit typically cost a few thousand dollars per pound, whereas most cars probably won't have a noticeable effect from a few pounds here or there. Now if you can start taking away several hundred pounds (possible with composites, though still expensive), then you start to get a significant effect.

mssmith95 · 07-10-2006, 06:25 PM

It is a great idea...but there has to be some reason that it never really caught on with other vehicles. Maybe a safety issue, maybe an electronics issue (it is hard to wire a car when you can not find a ground because the panels are plastic). It could also be that the repair costs on those panels was too high when compared with metal.

fuelsipper · 07-10-2006, 06:31 PM

<div class='quotetop'>QUOTE(Godiva @ Jul 10 2006, 04:51 PM) [snapback]284089[/snapback]</div>

Quote:

The side panels on my 1996 Saturn SC2 coupe were some sort of plastic. You could pound on them and they would give and bounce back. It was a selling point and after 10 years it didn't have any "dings". I imagine they would make the car lighter. You would need to reformulate the paint so it would be flexible like the panels. The frame was a cage to protect the passengers, much like the Prius.
[/b]

Hummm...I didn't know that about the Saturn. thank you for the information, and yes the question does arise...why not in other vehicles?

E-Eric

hobbit · 07-10-2006, 07:06 PM

If you get enough dings in something that holds its shape, then
you'll have those aerodynamic surface dimples that'll increase
your MPG!
.
... when the "golf cart" turns into the "golf ball" ...
.
_H*

daniel · 07-10-2006, 08:37 PM

I don't know. This is just a speculation: It could have to do with crumple zones as a safety factor. A body that takes an impact and then springs back into shape is not absorbing any energy. A body that crumples is absorbing energy. For safety you want the body of the car to absorb energy so that your own body doesn't.

donee · 07-10-2006, 09:31 PM

Oops...

**Tideland Prius** · 07-10-2006, 09:54 PM

Plastic panels mean larger gaps between panels which leads to ungainly gaps between panels and aerodynamic issues in that they create larger eddies.

fuelsipper · 07-10-2006, 10:45 PM

I have the answer why plastic type flexible body parts are not an industry standard!

ABAA

Auto Body Associates of America 8)

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07-10-2006, 05:45 PM	#1
fuelsipper Join Date: Aug 2005 Location: southern Oregon Posts: 63 My Car: Package: Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	material. I do not know the technical term, but am thinking plastic/kevlar, or some concoction thereof. Maybe that would be too expensive to make. And I just might find out... The point is...the body on the Prius is about as sturdy as a can of Hamms Beer (not that I would know how that tastes) I could go on with all of the body damage our 2005 Prius has aquired, most in parking lots (yes, we always look for a good spot, it still happens) I am wishing for a plastic body, one that pops back into shape. Way past the first dent phase, just wondering if anyone else has had a thought on the subject.. E-Eric

07-10-2006, 05:51 PM	#2
Godiva AmeriKan Citizen Join Date: Apr 2005 Location: San Diego, CA Posts: 10,022 My Car: 2005 Prius Package: #1 Nominated 3 Times in 2 Posts TOTM Awards: 0 Friends: 6	The side panels on my 1996 Saturn SC2 coupe were some sort of plastic. You could pound on them and they would give and bounce back. It was a selling point and after 10 years it didn't have any "dings". I imagine they would make the car lighter. You would need to reformulate the paint so it would be flexible like the panels. The frame was a cage to protect the passengers, much like the Prius.

07-10-2006, 06:10 PM	#3
jtullos Join Date: Jan 2006 Location: Dayton, NV Posts: 172 My Car: Package: Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	At present, making composites is neither easy nor cheap. I've done a very small amount of work with composites, and yes, they are lighter and stronger. However, composite production is not yet (to my knowledge) fully automated, certainly not on the scale necessary for a production automobile. Composites are not necessarily flexible. Some are, some aren't. It's all in how the composite is put together. What I worked with, and those I've seen, are all for rigid applications (airplane wings, rocket/satellite components, etc). These are all applications where a few pounds can make a huge difference in cost. Launches to orbit typically cost a few thousand dollars per pound, whereas most cars probably won't have a noticeable effect from a few pounds here or there. Now if you can start taking away several hundred pounds (possible with composites, though still expensive), then you start to get a significant effect.

07-10-2006, 06:25 PM	#4
mssmith95 "I think my Dad's gone CRAZY!" Join Date: Feb 2006 Location: Los Angeles Posts: 533 My Car: Package: Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	It is a great idea...but there has to be some reason that it never really caught on with other vehicles. Maybe a safety issue, maybe an electronics issue (it is hard to wire a car when you can not find a ground because the panels are plastic). It could also be that the repair costs on those panels was too high when compared with metal.

07-10-2006, 07:06 PM	#6
hobbit Senior Member Join Date: Mar 2005 Location: Bahstahn Posts: 2,989 My Car: Package: Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	If you get enough dings in something that holds its shape, then you'll have those aerodynamic surface dimples that'll increase your MPG! . ... when the "golf cart" turns into the "golf ball" ... . _H*

07-10-2006, 08:37 PM	#7
daniel Cat Lovers Against the Bomb Join Date: Feb 2004 Location: Spokane, WA Posts: 9,148 My Car: 2004 Prius Package: #6 Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	I don't know. This is just a speculation: It could have to do with crumple zones as a safety factor. A body that takes an impact and then springs back into shape is not absorbing any energy. A body that crumples is absorbing energy. For safety you want the body of the car to absorb energy so that your own body doesn't.

07-10-2006, 09:31 PM	#8
donee Senior Member Join Date: Aug 2005 Location: Chicagoland Posts: 1,539 My Car: 2006 Prius Package: #2 Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	Oops...

07-10-2006, 09:54 PM	#9
Tideland Prius Super Moderator Join Date: Oct 2004 Location: Canada Posts: 13,920 My Car: 2005 Prius Package: B Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 11	Plastic panels mean larger gaps between panels which leads to ungainly gaps between panels and aerodynamic issues in that they create larger eddies.

07-10-2006, 10:45 PM	#10
fuelsipper Join Date: Aug 2005 Location: southern Oregon Posts: 63 My Car: Package: Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	I have the answer why plastic type flexible body parts are not an industry standard! ABAA Auto Body Associates of America 8)