Load-bearing light-weight structures which are safer and stronger than the current in-use structures have a key role in the development of mobility and energy technologies. Hybrid modules consisting of plastic ribs and metal inserts combine the structural advantages of both materials so as to improve the net performance with relatively light weight. Steel sheet had been considered as a conventional insert for hybrid structures. Since serious global environmental problems are caused by automobile emissions such as COx and NOx, greenhouse effect; further reduction in the weight of motor vehicles is strongly recommended. Based on this need, further development of light-weight modules in this industry field had been accomplished with the aim to have a high relative strength; assure low cost, low energy consumption, compatibility with complex engineering structures and less effect on the environment.
Research group (Light-weight hybrid structures) at the Chair of Polymer Technology, Erlangen-Nuremberg University, Germany has current work which is related to the investigation of the potential for using of glass-reinforced fabrics instead of steel inserts as well as the creation of a new flexible assembly technique. A super light-weight hybrid structure has been produced, in less than 60 seconds and in one manufacturing step. This was possible by means of the new manufacturing technique called In-Mold-Forming (IMF), which has been developed at the Chair of Polymer Technology. The main innovation of this new technique is the possibility to integrate several process steps in one, which means shortening the production cycle-time. This has been realized by forming the insert thermoplastic-based fabric directly in the injection molding machine instead of being pre-formed in separate processing step. IMF has a considerable potential to be used in a cost-effective series production in many industrial fields especially automotive industry where light-weight performance with adequate load-bearing function is required. In order to demonstrate the applicability of the IMF-process, a steering column connection has been manufactured after conducting detailed modeling and experimental investigations.
Steering Column Connection Hybrid structure / Insert: TEPEX® dynalite 104-RG600(4); 45% Roving Glas/PP; 2,0 mm / Ribs: Stamax / PP-GF30 der Fa. Sabic
For further information you can contact:
Dipl.-Ing. (FH) Thomas Müller, muellert@lkt.uni-erlangen.de
M. Sc. Ahmad Al-Sheyyab , alsheyyab@lkt.uni-erlangen.de