In-Mold Foamed Cores for Lightweight Design

摘要

In sports, premium, and electric vehicles, e.g. the Alfa Romeo4C or BMWB and i8, the high stiffness and functional integration of fiber-reinforced plastics are increasingly being exploited for lightweight design. Typical lightweight automotive components are currently being used in auto bodies, monocoques, and chassis struts. When it comes to providing component stiffness, sandwich structures are unmatched. They consist of thin outer layers, e.g. made from carbon fiber-reinforced plastics (CFRP), combined with a lightweight but mechanically strong core, e.g. produced from plastic foam. With greater foam thickness, there is a disproportionately high increase in the stiffness of the component, while its weight remains minimal because of the low density of the foam.