Development of a mass production process for fibre-reinforced parts with transparent polyurethane matrix exemplarily for a CFRP seat back with a visible surface

由复合材料和聚氨酯（PU）作为基体材料制成的高性能部件已在许多工业应用中证明了其经济潜力。然而，所生产的部件的缺点是纤维体积含量低和使用发泡PU，这导致有限的机械性能。连续纤维织物聚氨酯喷涂浸渍技术的发展（树脂喷射预浸（RSP））结合研究单元（FOR 860）内的优化成型和固化工艺，可以在短周期内自动生产高性能部件，纤维体积含量高（> 50%）FOR 860的科学重点是开发生产技术和可实现的机械性能。对于特定的应用，需要对零件表面提出进一步的要求。该转移项目的目的是将FOR 860项目4和8的知识转移到具有规定表面质量的高度可重复零件的制造中，并生成详细的工艺知识。织物加固应是可见的，而不需要在表面上绘制其结构，以减少修补操作。为了实施生产技术，需要进一步的科学研究。由于其复杂性，这些调查只有通过工业公司和研究机构之间的跨学科合作才是可行的。在对FOR 860的研究中，可以证明，通过调整工艺和机械技术，制造几乎无孔的整体部件是可能的。为了使该技术能够用于制造具有规定表面性能的部件，将对试样进行系统研究，以确定原材料粘合剂、织物和PU系统对各种温度下机械性能的影响。接下来，使用两种平行的研究方法分析了纤维增强塑料部件的制造。调查将包括工艺、材料和预成型参数的变化以及模具技术的适应。为了符合工业要求，将在规定的时间内通过不同的环境条件（交变气候测试，紫外线辐射）测试表面性能。在对平面零件进行基础研究之后，将知识转移到轻量化设计中的座椅靠背上。所选座椅几何形状应能将知识传递到其他结构部件

High performance parts made from composites and polyurethane (PU) as matrix material have proven their economic potential in many industrial applications. However, the disadvantages of the produced parts are the low fibre volume content and the use of foamed PU, which leads to a limited mechanical performance. The development in the field of PU spray impregnation of continuous fibre textiles (Resin Spray Prepregging (RSP)) in combination with an optimised forming and curing process within the research unit (FOR860) allows the automated production of high performance parts in short cycle times with a high fibre volume content (> 50 %).The scientific focus of the FOR860 was the development of the production technology and the achievable mechanical properties. For specific applications, further requirements regarding the surface of the parts are requested. The aim of this transfer project is to transfer the knowledge of the projects 4 and 8 of the FOR860 to the manufacturing of highly loadable parts with a defined surface quality and to generate detailed process knowledge. The textile reinforcement should be visible without drawing its structure on the surface in order to reduce the refinishing operations. For an implementation of the production technology, there are further scientific investigations necessary. Because of the complexity, these investigations are only feasible by interdisciplinary cooperation between industrial companies and a research institute. Within the investigations of the FOR860, it could be shown, that by an adapted process and machine technology the manufacturing of almost pore-free monolithic parts is possible. To enable this technology for the manufacturing of parts with defined surface properties, systematic investigations on test specimens will be made to determine the influence of the raw materials binder, fabrics and PU-systems on the mechanical properties at various temperatures. Following that, the manufacturing of fibre-reinforced plastic parts is analysed using two parallel research approaches. The investigation will include a variation of the process, material and preforming parameters as well as an adaption of the tooling technology. To be consistent with the industrial requirements, the surface properties will be tested by different environmental conditions (alternating climate test, UV radiation) in defined times. The fundamental research on planar parts will be followed by the transfer of the knowledge to a seat back in lightweight design. The chosen geometry of the seat shall enable the knowledge transfer to other structural components