Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process
Sandwich structures utilize the geometric stiffening effect by increasing the area moment of inertia. This reduces carbon fiber (CF) material within CF-reinforced plastic (CFRP) components, and thus, the CO<sub>2</sub> footprint. A suitable material combination for lightweight design is...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-04-01
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| Series: | Journal of Composites Science |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2504-477X/5/4/104 |
| _version_ | 1797538064728326144 |
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| author | Felix Behnisch Viktoria Lichtner Frank Henning Philipp Rosenberg |
| author_facet | Felix Behnisch Viktoria Lichtner Frank Henning Philipp Rosenberg |
| author_sort | Felix Behnisch |
| collection | DOAJ |
| description | Sandwich structures utilize the geometric stiffening effect by increasing the area moment of inertia. This reduces carbon fiber (CF) material within CF-reinforced plastic (CFRP) components, and thus, the CO<sub>2</sub> footprint. A suitable material combination for lightweight design is the use of continuous fiber-reinforced face sheets with a light foam core. CFRP sandwich structures with foam core are manufactured by combining a prefabricated foam core with fiber-reinforced cover layers in a two-step press process. Besides the reduction of the used CFRP material, more efficient manufacturing processes are needed. The aim of this paper is to develop a novel polyurethane foam system to enable the direct sandwich composite molding (D‑SCM) process for the production of CFRP sandwich structures by utilizing the resulting foaming pressure during the reactive polyurethane (PUR) foam system expansion for the impregnation of the CF reinforced face sheets. The developed formulation enables D-SCM structures with 150–250 kg/m<sup>3</sup> foam density and 44–47.5% fiber volume content, based on a preliminary evaluation. |
| first_indexed | 2024-03-10T12:25:09Z |
| format | Article |
| id | doaj.art-7cedd56a67294a57abc9bd4d46f84baf |
| institution | Directory Open Access Journal |
| issn | 2504-477X |
| language | English |
| last_indexed | 2024-03-10T12:25:09Z |
| publishDate | 2021-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Composites Science |
| spelling | doaj.art-7cedd56a67294a57abc9bd4d46f84baf2023-11-21T15:05:09ZengMDPI AGJournal of Composites Science2504-477X2021-04-015410410.3390/jcs5040104Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) ProcessFelix Behnisch0Viktoria Lichtner1Frank Henning2Philipp Rosenberg3Fraunhofer-Institute for Chemical Technology ICT, Joseph-von-Fraunhofer Str. 7, 76327 Pfinztal, GermanyFraunhofer-Institute for Chemical Technology ICT, Joseph-von-Fraunhofer Str. 7, 76327 Pfinztal, GermanyFraunhofer-Institute for Chemical Technology ICT, Joseph-von-Fraunhofer Str. 7, 76327 Pfinztal, GermanyFraunhofer-Institute for Chemical Technology ICT, Joseph-von-Fraunhofer Str. 7, 76327 Pfinztal, GermanySandwich structures utilize the geometric stiffening effect by increasing the area moment of inertia. This reduces carbon fiber (CF) material within CF-reinforced plastic (CFRP) components, and thus, the CO<sub>2</sub> footprint. A suitable material combination for lightweight design is the use of continuous fiber-reinforced face sheets with a light foam core. CFRP sandwich structures with foam core are manufactured by combining a prefabricated foam core with fiber-reinforced cover layers in a two-step press process. Besides the reduction of the used CFRP material, more efficient manufacturing processes are needed. The aim of this paper is to develop a novel polyurethane foam system to enable the direct sandwich composite molding (D‑SCM) process for the production of CFRP sandwich structures by utilizing the resulting foaming pressure during the reactive polyurethane (PUR) foam system expansion for the impregnation of the CF reinforced face sheets. The developed formulation enables D-SCM structures with 150–250 kg/m<sup>3</sup> foam density and 44–47.5% fiber volume content, based on a preliminary evaluation.https://www.mdpi.com/2504-477X/5/4/104sandwich structuresCFRPadvanced compositespolyurethane foamD-SCM |
| spellingShingle | Felix Behnisch Viktoria Lichtner Frank Henning Philipp Rosenberg Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process Journal of Composites Science sandwich structures CFRP advanced composites polyurethane foam D-SCM |
| title | Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process |
| title_full | Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process |
| title_fullStr | Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process |
| title_full_unstemmed | Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process |
| title_short | Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process |
| title_sort | development of a reactive polyurethane foam system for the direct sandwich composite molding d scm process |
| topic | sandwich structures CFRP advanced composites polyurethane foam D-SCM |
| url | https://www.mdpi.com/2504-477X/5/4/104 |
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