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

以复合材料和聚氨酯（PU）为基体材料制成的高性能部件在许多工业应用中已经证明了它们的经济潜力。然而，所生产部件的缺点是纤维体积含量低，使用发泡PU，导致机械性能有限。连续纤维纺织品的PU喷雾浸渍（树脂喷雾预浸（RSP））领域的发展，结合研究单元（FOR860）的优化成型和固化工艺，可以在短周期内以高纤维体积含量（bbb50 %）自动化生产高性能部件。FOR860的科学重点是生产技术的发展和可实现的力学性能。对于特定的应用，对零件表面有进一步的要求。该转移项目的目的是将FOR860项目4和项目8的知识转移到具有确定表面质量的高可装载部件的制造中，并生成详细的工艺知识。织物增强物不应在表面上画出其结构，以减少修补作业。为了实现生产技术，还需要进一步的科学研究。由于其复杂性，这些研究只有通过工业公司和研究机构之间的跨学科合作才能实现。在FOR860的调查中，可以表明，通过适应的工艺和机器技术，制造几乎无孔的整体零件是可能的。为了使这项技术能够制造具有确定表面性能的零件，将对测试样品进行系统的调查，以确定原材料粘合剂，织物和pu系统在不同温度下对机械性能的影响。然后，采用两种平行的研究方法对纤维增强塑料零件的制造进行了分析。调查将包括工艺，材料和预成型参数的变化，以及工具技术的适应。为了与工业要求保持一致，表面性能将在规定的时间内通过不同的环境条件（交替气候试验，紫外线辐射）进行测试。在平面零件的基础研究之后，将知识转移到轻量化设计的座椅靠背上。所选择的阀座几何形状应该能够将知识转移到其他结构部件上

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