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- Title
Mold technology for mass production of continuous fiber-reinforced sandwich parts.
- Authors
Hopmann, Christian; Wagner, Philipp N.; Bastian,, Robert; Fischer, Kai; Böttcher, Arne
- Abstract
In order to reduce cycle times, increase functional integration and automation further, the innovative gap impregnation process and mold technology was developed at the Institute of Plastics Processing at RWTH Aachen University (Germany) in collaboration with industry partners. The novel process enables an automated production of continuous fiber-reinforced sandwich composite structures in integral design with high surface quality in short cycle times, which is demonstrated by manufacturing a carbon fiber-reinforced plastic (CFRP) engine hood. For the first time, the gap impregnation and mold technology makes it possible to manufacture largescale, three-dimensionally shaped sandwich components in one shot and in short cycle times at similar mechanical properties compared to the reference steel hood. Furthermore, a weight reduction of about 60% to only 5 kg was achieved for the CFRP engine hood. This paper focuses on the systems engineering of the RTM-related gap impregnation process. The focus is on the utilized mold concepts for the pressurized air-assisted ejector pins, vacuum-tight sealing, the motion concept of the mold halves, resin traps, sensors for process control and the specially treated mold surfaces for class A surface components. Additionally, the main procedures, capabilities and characteristics of this innovative process are discussed.
- Subjects
FIBER-reinforced plastics; MASS production; MOLDING of plastics; MANUFACTURING process automation; SANDWICH construction (Materials)
- Publication
Journal of Polymer Engineering, 2016, Vol 36, Issue 6, p589
- ISSN
0334-6447
- Publication type
Article
- DOI
10.1515/polyeng-2015-0149