Lightweight design at Volkswagen: Via thermoset pultrusion to the production of fiber-reinforced plastics for a load path in the door structure with high-volume production potential

摘要

This contribution focuses on the application of thermoset pultrusion for a cost-effective production with high-volume capability of fiber-reinforced plastics (FRP) in the mid-size car segment at Volkswagen. In addition to thermoset pultrusion as a process, a description is also given of an iterative approach consisting of component design, numerical validation and final experimental testing for the development of a so-called FRP door sill tube. One significant result is success in passing a small-overlap crash test. This qualifies the FRP door sill tube for a series application.