Combined Injection Molding Technology for Dynamically Stressed Multi-Material Coupling Elements

Abstract:

The manufacturing of high load components in automotive and mechanical engineering demands for an increased usage of combined plastics processing procedures. In practice, full plastic hybrid components are produced in a series of individual processes such as thermoforming or injection molding. The constructive implementation has often only material-substituting character wherein the high potential for lightweight anisotropic fiber composites is exploited only to a limited extent. Based on the application of a coupling brace in a vehicle, a new component design for function-integrated interface elements is enabled by an integrated injection molding technology. The targeted transfer of high local stresses by load-bearing insert elements regarding contoured metal sheets or Fiber Reinforced Thermoplastic Composites (TP-FRC) semi-finished products with endless fiber reinforcement enables efficient dimensioning of components. This fusion of technologies to a Multi Material Design (MMD) form the basis for novel weight-optimized, as well as cost-effective applications and lead to a high bending stiffness and high strength of structures. The composite strength of MMD components is increased by a variation and optimization of the thermoplastic/TP-FRC respectively thermoplastic/metal-interfaces. This objective will be achieved by highly efficient and integrated process flows and by the new entire construction of the component.

• Periodical: Key Engineering Materials (Volume 744)
• Pages: 322-326
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.744.322
• Online since: July 2017
• Authors: Tristan Timmel*, Alexander Hackert, Tomasz Osiecki, Colin Gerstenberger, Lothar Kroll
• Keywords: Carbon Fiber Reinforced Plastics (CFRP), Composite Material, Compound Adhesion, Hybrid, Lightweight Structures, Multi-Material-Design, Post-Mold-Assembly, Resource Efficient Production

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