Abstract
Due to the stringent emission reduction targets, imposed in Europe and all over the world, and the need for more efficient use of resources, both lightweight solutions and alternative mobility concepts are high priorities in the research agenda of the automotive sector. Besides, with the exponential growth of population living in urban areas mobility solutions, going beyond the traditional car, are needed towards reduction not only of emissions but also of traffic congestion
Vehicles specifically developed for use in urban environment have often very different requirements compared to traditional ones. This opens interesting opportunities for the use of alternative and innovative materials for the body of such vehicles. First of all, a study has been carried out to identify the specific needs of city vehicles, in terms of both the product itself and its interaction with the environment, based both on subjective user feedback and benchmark. Starting from a lightweight sandwich material developed in a previous project, further research and development has been performed to match the technical requirements with the lowest possible weight. The optimised material has then been integrated and validated in a prototype.
In this paper the development of the sandwich material, consisting of fiber reinforced polyurethane skins and a polyurethane foam core, will be presented. The optimisation of the material performance to meet the requirements of new alternative city vehicles has enabled to combine interior and exterior of the vehicle body in one material, leading to additional weight saving. Tests carried out both on sample level and on a full-vehicle prototype have validated the lightweight sandwich material.
KEYWORDS : Composites, Lightweight, Structural components