Description:APPARATUS FOR FORMING ONE OR MORE COMPONENTS OF A VEHICLE
FIELD OF THE DISCLOSURE
[0001] This invention generally relates to a field of automotive materials and vehicle component manufacturing, and in particular, relates to a sustainable composite material and an apparatus for forming vehicle components using renewable natural fibres.
BACKGROUND
[0002] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
[0003] In the automotive industry, there is a growing demand for materials that combine strength, durability, and sustainability. Conventional vehicle components are commonly made using Polypropylene (PP) filled with talc or other non-renewable mineral fillers to improve mechanical properties such as stiffness, strength, and heat resistance. While these materials meet performance requirements, they pose significant environmental concerns.
[0004] Talc, a widely used filler in PP composites, is a non-renewable mineral obtained through mining processes that contribute to resource depletion and environmental degradation. Additionally, talc-filled composites are relatively heavy, adding extra weight to vehicle components, which can negatively impact fuel efficiency and carbon emissions. Efforts to replace talc with eco-friendly alternatives have faced challenges in maintaining the required mechanical properties, thermal stability, and manufacturing compatibility. Natural fibre composites have emerged as a potential solution; however, issues such as poor fibre-matrix adhesion, reduced durability, and inconsistent performance have limited their widespread adoption.
[0005] According to a patent application “US9809702B2” titled as “Hybrid sustainable composites and methods of making and using thereof” disclosed as the invention relates to composites containing one or more synthetic plastics, such as thermoplastics, one or more natural materials, such as plant/tree fibers, and biochar and/or torrefied material are described herein. The composite can contain additional additives, such as reinforcing agents and/or fibers, compatibilizers, etc. The composites have improved mechanical and/or physical properties, such as strength, impact strength, rigidity/modulus, heat deflection temperature, moldability/melt flow index, renewability, and lower cost compared to composites that do not contain the biochar and/or torrefied material. The presence of the biochar and/or torrefied material also serves to remove the odour often associated with natural fibers and other additives.
[0006] According to another patent application “IN202231044710A” titled as “Light-weight, jute fibre or jute stick or jute caddies based reinforced composite components” disclosed as the invention relates to a moldable bio-filler filled polymer composition and composite product comprising synergistic co-acting blend of 2-6% compatibilizer/surface active agent incorporated bio-filler/s and polymer/s, wherein said compatibilizer/surface active agent includes functionalized thermoplastic polymers of maleic acid grafted polyolefin/s adapted for improved mechanical strength and reduced density. Bio fillers in the range of 20-70% include cellulosic fillers, jute stick flour, stapled jute caddies, stapled decani wool, raw natural fibre or agro waste such as jute, hemp, kenaf, sisal, bagasse, bamboo, wheat straw, rice straw, corn stalk, wood floor. The process of the present invention comprises the two steps: melt blending of cellulosic or bio fillers such as caddis, jute stick flakes and decani wool in the presence of compatibilizer or surface active agents under high temperature and shear which precisely disperse the cellulosic or bio filler in the polymer matrix, and then sheet making using extrusion-calendaring technology.
[0007] However, the disclosed inventions do not disclose about the use of the composites in handle grips and the specific percentages of bagasse and bamboo. Therefore, there is a need for a sustainable composite material that not only reduces reliance on non-renewable resources but also offers enhanced mechanical strength, thermal stability, and cost-effectiveness for use in vehicle components.
 
OBJECTIVES OF THE INVENTION
[0008] The objective of present invention is to provide a sustainable composite material for use in vehicle components that addresses the limitations of conventional talc-filled Polypropylene (PP) composites.
[0009] Further, the objective of the present invention is to develop a composite material that incorporates renewable natural fibres, such as Bagasse and Bamboo, to reduce reliance on non-renewable fillers while maintaining or improving mechanical performance.
[0010] Furthermore, the objective of the present invention is to implement a specialized fibre treatment process that enhances fibre-matrix adhesion, ensuring improved mechanical strength, flexural modulus, and impact resistance for enhanced durability.
[0011] Furthermore, the objective of the present invention is to provide a composite material that is equivalent to heat resistance as conventional materials making it suitable for demanding environments.
[0012] Furthermore, the objective of the present invention is to create a material that is lightweight, thereby contributing to improved fuel efficiency in vehicles without compromising structural integrity.
[0013] Furthermore, the objective of the present invention is to deliver a cost-effective solution by utilizing affordable agricultural waste materials such as Bagasse, reducing production costs compared to traditional talc-filled PP composites.
[0014] Furthermore, the objective of the present invention is to support environmentally sustainable manufacturing practices by promoting the use of biodegradable, renewable, and recyclable materials, ultimately reducing the environmental footprint of vehicle production.
 
SUMMARY
[0016] According to an aspect, the present embodiments discloses an apparatus for forming one or more components of a vehicle. The apparatus comprises a composite material. The composite material comprises a polypropylene (PP) matrix and a fibre reinforcement component uniformly dispersed within the PP matrix. The fibre reinforcement component is present in a predefined amount ranging from 20% to 30% by weight of the composite material. Further, the fibre reinforcement component undergoes a specialized treatment process to enhance fibre-matrix adhesion.
[0017] In some embodiments, the one or more components comprises at least one of a grip handle and an air duct.
[0018] In some embodiments, the fibre reinforcement component comprises at least one of a bagasse fibre and a bamboo fibre.
[0019] In some embodiments, the fibre reinforcement component comprises at least 30% of the bagasse fibre and 20% of the bamboo fibre. The bagasse fibre is used to form the grip handle and the bamboo fibre is used to form the air duct.
[0020] In some embodiments, the composite material exhibits a heat deflection temperature (HDT) of at least 118°C when the bagasse fibre is used and at least 157°C (98°C) when the bamboo fibre is used.
[0021] In some embodiments, the composite material exhibits a flexural modulus of at least 2600 mega Pascal (MPa) when the bagasse fibre is used and at least 4380 (1600MPa) when the bamboo fibre is used.
[0022] In some embodiments, the composite material exhibits a tensile strength of at least 30 MPa when the bagasse fibre is used and at least (22MPa) when the bamboo fibre is used.
[0023] In some embodiments, the composite material exhibits a melt flow rate of at least 9 g/10min when the bagasse fibre is used and at least 8 g/10min when the bamboo fibre is used.
[0024] In some embodiments, the composite material has a moulding shrinkage rate of no greater than 0.8% when the bagasse fibre is used and no greater than (1.22) % when the bamboo fibre is used.
[0025] According to an aspect, the present embodiments, discloses a method. The method comprises the steps of providing a polypropylene (PP) matrix. Further, the method comprises steps of providing a fibre reinforcement component uniformly dispersed within the PP matrix. The fibre reinforcement component is present in a predefined amount ranging from 20% to 30% by weight of the composite material. The fibre reinforcement component undergoes a specialized treatment process to enhance fibre-matrix adhesion.
 
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings illustrate various embodiments of systems, methods, and embodiments of various other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g. boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. It may be that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa. Furthermore, elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles.
[0027] FIG. 1 illustrates a block diagram of an apparatus for forming one or more components of a vehicle, according to an embodiment of the present invention;
[0028] FIG. 2A illustrates an isometric view of a grip handle, according to an embodiment of the present invention;
[0029] FIG. 2B illustrates a front view of the grip handle, in accordance to an embodiment of the present invention;
[0030] FIG. 2C illustrates a top view of the grip handle, in accordance to an embodiment of the present invention;
[0031] FIG. 2D illustrates a back view of the grip handle, in accordance to an embodiment of the present invention;
[0032] FIG. 3A illustrates an isometric view of an air duct, according to an embodiment of the present invention;
[0033] FIG. 3B illustrates a front view of the air duct, in accordance to an embodiment of the present invention;
[0034] FIG. 3C illustrates a top view of the air duct, in accordance to an embodiment of the present invention;
[0035] FIG. 3D illustrates a back view of the air duct, in accordance to an embodiment of the present invention; and
[0036] FIG. 4 illustrates a flowchart showing a method for forming the one or more components of the vehicle, according to an embodiment of the present invention.
 
DETAILED DESCRIPTION
[0038] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0039] Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the preferred, systems and methods are now described. Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.
[0040] FIG. 1 illustrates a block diagram of an apparatus (100) for forming one or more components of a vehicle, according to an embodiment of the present invention. FIG. 2A illustrates an isometric view of a grip handle (200), according to an embodiment of the present invention. FIG. 2B illustrates a front view of the grip handle (200), in accordance to an embodiment of the present invention. FIG. 2C illustrates a top view of the grip handle (200), in accordance to an embodiment of the present invention. FIG. 2D illustrates a back view of the grip handle (200), in accordance to an embodiment of the present invention. FIG. 3A illustrates an isometric view of an air duct (300), according to an embodiment of the present invention. FIG. 3B illustrates a front view of the air duct (300), in accordance to an embodiment of the present invention. FIG. 3C illustrates a top view of the air duct (300), in accordance to an embodiment of the present invention. FIG. 3D illustrates a back view of the air duct (300), in accordance to an embodiment of the present invention.
[0041] In some embodiments, the apparatus (100) for forming the one or more components of the vehicle comprises a composite material. The composite material comprises a polypropylene (PP) matrix (102) and a fibre reinforcement component (104) uniformly dispersed within the PP matrix (102). The one or more components comprises at least one of a grip handle (200) and an air duct (300).
[0042] In some embodiments, the fibre reinforcement component (104) is present in a predefined amount ranging from 20% to 30% by weight of the composite material. The fibre reinforcement component (104) comprises at least one of a bagasse fibre and a bamboo fibre.
[0043] In some embodiments, the fibre reinforcement component (104) comprises at least 30% of the bagasse fibre and 20% of the bamboo fibre. The bagasse fibre is used to form the grip handle (200) and the bamboo fibre is used to form the air duct (300). The fibre reinforcement component (104) corresponds to renewable natural fibres.
[0044] In some embodiments, the bagasse fibre corresponds to an agricultural waste. The bagasse fibre is a by-product of sugarcane industry. The bagasse fibre and the bamboo fibre corresponds to a light-weight composite. In some embodiments, the grip handle (200) is formed using 70% PP and 30% bagasse fibre. Further, the air duct (300) is formed using 80% PP and 20% bamboo fibre.
[0045] In some embodiments, the fibre reinforcement component (104) undergoes a specialized treatment process to enhance fibre-matrix adhesion. The fibre reinforcement component (104) is exposed to alkaline solutions, saline coupling agents, or maleic anhydride-grafted PP to improve surface roughness and bonding characteristics.
[0046] In some embodiments, the fibre reinforcement component (104) further undergoes chemical treatment. One or more impurities is removed from the fibre reinforcement component (104). Removing the one or more impurities enhances the fibre reinforcement component (104) stability, and improves thermal properties of the fibre reinforcement component (104).
[0047] In some embodiments, the fibre reinforcement component (104) further undergoes drying process. The apparatus (100) ensures the treated fibre reinforcement component (104) have an optimal moisture content before blending with the PP matrix (102) to maintain material stability.
[0048] In some embodiments, the melt flow rate indicates how easily the material flows during the moulding process. A higher value of the melt flow rate corresponds to better flow. The melt flow rate for the bagasse fibre corresponds to 9g/10min. Further, the melt flow rate for the bamboo fibre corresponds to 8g/10min.
[0049] In some embodiments, the specific gravity corresponds to material density. Lower value of the specific gravity indicates lighter weight. The lighter weight can improve vehicle fuel efficiency. The specific gravity for the bagasse fibre corresponds to (0.90). Further, the specific gravity for the bamboo fibre corresponds to (0.99).
[0050] In some embodiments, the flexural modulus corresponds to material stiffness. Higher value of the flexural modulus mean the material resists bending is better. The flexural modulus for the bagasse fibre corresponds to 2600. Further, the flexural modulus for the bamboo fibre corresponds to (1600). The bagasse fibre has a higher stiffness.
[0051] In some embodiments, the flexural strength indicates how much force the material can handle before breaking when bent. The flexural strength for the bagasse fibre corresponds to 58. Further, the flexural strength for the bamboo fibre corresponds to (36).
[0052] In some embodiments, the tensile strength measures the material's ability to resist pulling forces. The tensile strength for the bagasse fibre corresponds to 30. Further, the tensile strength for the bamboo fibre corresponds to (47).
[0053] In some embodiments, elongation at yield indicates how much the material can stretch before breaking. The elongation at yield is represented in terms of percentage (%). The value for the elongation at yield for the bagasse fibre corresponds to 3.8%. Further, the value for the elongation at yield for the bamboo fibre corresponds to (3.2) %.
[0054] In some embodiments, the tensile modulus measures stiffness under tension. The tensile modulus for the bagasse fibre corresponds to 1200. The tensile modulus is represented in terms of MPa. Further, the tensile modulus for the bamboo fibre corresponds to (1690).
[0055] In some embodiments, the HDT indicates the material's ability to maintain shape under heat. The HDT for the bagasse fibre corresponds to 1180C. Further, the HDT for the bamboo fibre corresponds to (98°C).
[0056] In some embodiments, the moulding shrinkage indicates how much the material shrinks after moulding. The moulding shrinkage for the bagasse fibre corresponds to 0.8%. Further, the moulding shrinkage for the bamboo fibre corresponds to (1.22) %.
[0057] In some embodiments, the ratio of the PP to the fibre reinforcement component (104) can be adjusted to optimize characteristics such as strength, flexibility, thermal resistance, and weight reduction. This allows for tailored formulations suited to one or more components of the vehicle, ensuring optimal performance across a range of structural and non-structural applications. Further, variations in the fibre treatment processes, such as surface modifications and coupling agents, enable further refinement of adhesion properties, improving durability and processing efficiency.
[0058] In some embodiments, the composite material represents an industry-first unique blend specifically designed for automotive applications. The innovative material formulation has been co-developed with a supplier, ensuring that it meets stringent performance, sustainability, and manufacturability standards. The composite material incorporates natural fibres while maintaining equivalent or superior mechanical properties. The development process has involved extensive material testing, supplier collaboration, and iterative optimization.
[0059] FIG. 4 illustrates a flowchart showing a method (400) for forming the one or more components of the vehicle, according to an embodiment of the present invention.
[0060] At operation 402, the method (400) is configured to provide the PP matrix (102). The PP matrix (102) is selected based at least on one or more properties. The one or more properties includes at least one of lightweight characteristics, mould ability, and resistance to heat and chemicals. The PP matrix (102) is provided in the form of pellets, granules, or powder to facilitate uniform mixing with the fibre reinforcement component (104).
[0061] At operation 404, the method (400) is configured to provide the fibre reinforcement component (104). The fibre reinforcement component (104) is present in the predefined amount ranging from 20% to 30% by weight of the composite material. The fibre reinforcement component (104) further undergoes the specialized treatment process to enhance the fibre-matrix adhesion.
[0062] It should be noted that the apparatus in the vehicle in any case could undergo numerous modifications and variants, all of which are covered by the same innovative concept; moreover, all of the details can be replaced by technically equivalent elements. In practice, the components used, as well as the numbers, shapes, and sizes of the components can be of any kind according to the technical requirements. The scope of protection of the invention is therefore defined by the attached claims.
, Claims:WE CLAIM:
1. An apparatus (100) for forming one or more components of a vehicle comprising:
a composite material comprising:
a polypropylene (PP) matrix (102); and
a fibre reinforcement component (104) uniformly dispersed within the PP matrix (102),
wherein the fibre reinforcement component (104) is present in a predefined amount ranging from 20% to 30% by weight of the composite material, and
wherein the fibre reinforcement component (104) undergoes a specialized treatment process to enhance fibre-matrix adhesion.

2. The apparatus (100) as claimed in claim 1, wherein the one or more components comprises at least one of a grip handle (200) and an air duct (300).

3. The apparatus (100) as claimed in claim 1, wherein the fibre reinforcement component (104) comprises at least one of a bagasse fibre and a bamboo fibre.

4. The apparatus (100) as claimed in claim 3, wherein the fibre reinforcement component (104) comprises at least 30% of the bagasse fibre and 20% of the bamboo fibre, and wherein the bagasse fibre is used to form the grip handle (200) and the bamboo fibre is used to form the air duct (300).

5. The apparatus (100) as claimed in claim 3, wherein the composite material exhibits a heat deflection temperature (HDT) of at least 118°C when the bagasse fibre is used and at least (98°C) when the bamboo fibre is used.

6. The apparatus (100) as claimed in claim 3, wherein the composite material exhibits a flexural modulus of at least 2600 mega Pascal (MPa) when the bagasse fibre is used and at least (1600MPa) when the bamboo fibre is used.

7. The apparatus (100) as claimed in claim 3, wherein the composite material exhibits a tensile strength of at least 30 MPa when the bagasse fibre is used and at least (22MPa) when the bamboo fibre is used.

8. The apparatus (100) as claimed in claim 3, wherein the composite material exhibits a melt flow rate of at least 9 g/10min when the bagasse fibre is used and at least 8 g/10min when the bamboo fibre is used.

9. The apparatus (100) as claimed in claim 3, wherein the composite material has a moulding shrinkage rate of no greater than 0.8% when the bagasse fibre is used and no greater than (1.22) % when the bamboo fibre is used.

10. A method for providing one or more components of a vehicle comprising:
providing a polypropylene (PP) matrix (102); and
providing a fibre reinforcement component (104) uniformly dispersed within the PP matrix (102),
wherein the fibre reinforcement component (104) is present in a predefined amount ranging from 20% to 30% by weight of the composite material, and
wherein the fibre reinforcement component (104) undergoes a specialized treatment process to enhance fibre-matrix adhesion.