Car Body Design with Polyurethane Composites Produced by an Innovative Pultrusion Process

Abstract

An innovative pultrusion process makes it possible to produce fiber reinforced polyurethane composites with superior mechanical properties compared to most traditional lightweight materials. The outstanding mechanical properties can be achieved, due to a very high fibre volume fraction. Moreover in the highly automated manufacturing process, lineal profiles with highly complex cross-section can be realized with minimal production cost. As a technology demonstrator, in this study, the new pultruded composite will be implemented in a car body of a hydrogen powered vehicle. While the prototype testing’s of the materials performance are planned in a DTM (DTM: Deutsche Tourenwagen-Meisterschaft) racing car, the long term vision focuses on an urban car concept, designed completely with this innovative material. The pultruded composite, as an attractive automotive design material, reduces weight and consequently cuts emissions and environmental damages. It can be a promising step towards increased sustainability.