Material Selection and Process Configuration for Free-Form, Voluminous and Textile-Based Multi-Material-Design by the Example of a Bucket Seat

Abstract

Hybrid textile-based composites possess an enormous potential for energy and resource efficient large-scale production, with freedom in and high specific mechanical properties. This paper covers the connection of available and established production processes for textiles in a differential process chain for the manufacturing of complex shaped and elastic sandwich components. The technology enables both stiffness and comfort through elasticity.OLU-Preg®-organic sheets, polyurethane foam cores and 3D-spacer fabrics form the targeted properties of demonstrator models. This article refers to the demonstrator part “bucket seat”. To show the benefit of complex composite material, the lightweight and mechanical properties of the sandwich structures are tested in several variations of core and comfort shapes. Absolute and specific improvements of performance are shown in static and dynamic examinations. An Analysis of coupling effects, deformation and failure behavior of the multi-material design (MMD) complete the scientific approach of the structure-property relationships of hybrid composites.

Strategy and numerical modelling of a vehicle seat with a lightweight sandwich design for large-scale production

“…Based on the current investigations [2,10,11], a pressing process with integrated foam injection moulding needs to be developed (Figure 7). Initially, two thermoplastic prepreg sheets need to be preheated at a defined temperature, e.g.…”

Lightweight Potential of 3D Endless Fiber Reinforcement of Polyurethane Foam Cores with Spacer Fabrics in Hybrid Sandwich Structures with Fiber Reinforced Thermoplastic Facings

“…This are in contrast easily recyclable [3]. Components made of thermoplastic facings and a thermoset core can be designed very freely [4]. A good forming ability of the thermoplastics and the high flowability of thermoset foams are the reasons for this.…”

Investigation of the specific adhesion between polyurethane foams and thermoplastics to suited material selection in lightweight structures

“…The resulting compound design allows immense freedom in the component design because of the high degrees of deformation of fibre-reinforced TPs, the drapability of spacer fabrics and the high flowability of PUR foams. [22][23][24] The environmentally friendly recycling of components consisting of various fibres and thermoset as well as TP resins challenges the industry and the research. 25 Different approaches for mechanical, thermal and chemical recycling are used.…”

“…The resulting compound design allows immense freedom in the component design because of the high degrees of deformation of fibre-reinforced TPs, the drapability of spacer fabrics and the high flowability of PUR foams. 22 –24…”