Subproject B5

Main aim of the sub-project B5 is the research of a production technology for manufacturing of piezo-active sandwich components by injection moulding. During the manufacturing process piezoceramic components are bonded with fibre-reinforced thermoplastic or light weight alloys. Thereby a sandwich with a thermoplastic core-component is obtained. This allows both functional and geometric modifications in a wide range and consequently leads to a manifold application capability.
The need to integrate piecoelectric elements as sensors and actors in light-weight components results from the demand for smart light-weight applications. In our vision it evolves into a capable production technology. By using injection moulding as assembling technique several scientific questions on complex material interactions arise.
The integrated assembling of the piezo composites inline with the injection moulding process is the key to the production of function-integrated components (smart components). Furthermore, injection molding is a primary forming technique, which allows the economical production of out-of-tool parts in great quantities. A transfer moulding machine, which combines special technologies, is the basis for this integrated assembling.
During this research project both thermoplastic and thermoset pieco-electric elements should be integrated in the sandwich components. By adequate pre-treatment (e.g. plasma treatment) a superficial bond with the hybrid sandwich component has to be achieved. The resulting compound strength as well as the effective interactions between the individual project stages will be analysed.
To rate the heat balance during the whole process chain and to predict the material behaviour of the single layers, the sandwich structure will be modelled and simulated with the determined properties. Furthermore the FE-method as simulation tool will help to gain information about the shear stress which occurs during the production process. Thus, the damageable piezo-ceramic composites can be inserted gently.