Lightweight design through multi-material systems - Structural cabin parts made of continuous-fiber-reinforced thermoplastic material with a polyurethane outer skin in Class A quality

摘要

The aim of the MultiKab research project funded by BMBF was to develop new weight and cost-optimized multi-material systems for commercial vehicle cabins (trucks and agricultural machinery). The focus of the investigations was on a structurally robust, continuous fiber-reinforced thermoplastic carrying structure (organic sheet) which is positively bonded with a fiber-reinforced, duroplastic polyurethane outer skin in Class A quality. Research was successfully carried out in the project consortium on the materials, manufacturing and joining technologies, and on adapted simulation methods. To minimize any fiber markings on the visible side of the component, polyurethane systems were developed to create a suitable surface quality for outer skin components. To this end, adapted processing technologies were prepared for PUR-LFI (Long Fiber Injection), IMP (In-Mold Painting) and CCM (Clear-Coat Molding). In addition, adapted material cards and CAE modeling technologies were developed, and the joins fully characterized with regard to surface texture and interfacial energy. Finally, a function demonstrator was used to validate the work.