Surface modelled after shark skin

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FRIMO Group GmbH

Functionally-optimized multi-sandwich in 3D format

As part of further development, a comparatively complex three-dimensional component had to be selected as a demonstration part in contrast to previous parts that were flatter. A Corvette rear wing was chosen. Such a component, through its special cross-section and the resulting different air velocities on the upper and underside, leads to increased downforce for the vehicle on the road. A weight-optimized sandwich construction is used for the new Street Shark 4.0. In doing so, the manufacturing process for a three-dimensional foam core on a serial production scale is the focal point here.

Previously, a variety of core materials were used for the different sandwich structures, such as PET, PP or PUR foams as well as balsa wood or bamboo in the form of plates or sheets. Flat sandwich plates produced in this manner were necessary at the beginning of development and helpful in documenting results on real components as well as in interesting potential customers about the sandwich principle and manufacturing process, and to convince them of its advantages.

Over the course of continued development by Frimo, more complex three-dimensional sandwich structures can now immediately be produced from polyurethane using molded foams. For this purpose, a test tool was designed in which the three-dimensional core was first produced using hard PU foam. In addition to the tool and mold carriers, the Frimo TechCenter also features a PURe Mix metering unit specially designed for matrix materials. Even while manufacturing the lightweight core, it is possible to integrate additional functions, such as for example taking fixation points or electronic elements into account.

Gallery

Once the three-dimensional core is produced, the external skins are produced from a fiber structure by use of a special PU matrix system with a Frimo high-pressure RTM process. The first step is to insert the lower layer of the preform made from reinforced fibers (carbon, glass, natural) into an RTM tool. The molded foam core and then finally the upper fiber layer is inserted. After that, the RTM tool is closed and a special-low viscosity PU matrix system is introduced.

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