Modular Car Design for Reuse

Abstract

The design of reusable composite structures for cars needs high constructional effort. The car must be divided into separable modules meeting ecologic and economic requirements. Here, a battery containing platform and a seating structure were selected as large components with high potential for reuse. In a first step the desired car is described setting the basic scenario. A carsharing vehicle shows perfect conditions due to low logistics effort and the business model of the owner. This sets the boundary conditions for the design of the platform. Two different approaches were tested and merged into a concept ready for reuse. Simulations of the stiffness and the crash performance show good values. First large CFRP profiles were produced in a complex pultrusion process. An associated seating structure following similar design principles was constructed using profiles and nods. All load-cases that can occur during the utilization phase could be beared. Both modules together can form the basis of a reusable car. The design principles like detachable joints—in particular the utilization of detachable adhesive connections—can be adapted for any other technical composite product.