Abstract
Sandwich structures consisting of fibre-reinforced plastic (FRP) facings and core are ideally suited as substitution materials for reducing component masses. The endless fibre reinforcement has the greatest performance potential. Both thermoset and thermoplastics are already being processed into endless fibre-reinforced sandwich facings according to the state of the art. The 3D endless fibre reinforcement of cores is a current research topic. This paper describes the development of a hybrid sandwich consisting of thermoplastic composite facings and an innovative core composite. This is made of polyurethane (PUR) rigid or flexible foam, which is reinforced with spacer fabric. The sandwich manufacturing in Reaction Injection Moulding (RIM) includes the original forming of the core and the simultaneous bonding of the facings. This efficient process offers the potential for the production of such complex structures in medium or large series. The sandwich structures and their individual components were characterised in the standardised compression and bending test. The lightweight potential of spacer fabric reinforcement is demonstrated by comparing the specific mechanical properties of sandwich structures with and without core reinforcement. In comparison to reinforced and unreinforced foams, the effect of sandwich design is also shown.
Highlights
Introduction and State of the ArtThe lightweight design reduces the mass of components while maintaining product functionality
The focus was on a sandwich thickness of 40 mm in order to demonstrate the potential of spacer fabrics for 3D endless fibre reinforcement of thick cores for special thermal and sound insulation requirements
In the mass-related, specific comparison (Fig. 3, b), the sandwich with core reinforcement drops behind the other rigid materials because of the mass proportions of the core reinforcement and the thermoplastic composite facings
Summary
Introduction and State of the ArtThe lightweight design reduces the mass of components while maintaining product functionality. Thermoplastics are already being processed into endless fibre-reinforced sandwich facings according to the state of the art [6]. This paper deals with the addition of such core composites with endless fibre-reinforced thermoplastic facings to sandwiches. Core composites with spacer fabric reinforcement were manufactured in the in-situ foaming with polyurethane and simultaneously bonded to thermoplastic facings.
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
