Paper-metal sheet composite II

The "paper-metal sheet composite" project demonstrated the successful use of paper in combination with sheet metal as a lightweight component and its potential for use in vehicle and equipment construction. One of the major problems was the lack dimensional stability due to the moisture absorption of the paper fibers. This affected also the dimensional stability of the overall composite and led to profile distortions on the outer layer of the sheet.

The object of the present research project is to expand the lightweight potential of paper-based laminated composites and to increase the ecology and sustainability character of the components. However, the dimensional stability of the paper honeycombs remains problematic, which is why additional layers have to be incorporated into the composite to prevent the honeycomb structure from drawing on the roof skin and thus continue to ensure a Class A surface.

The aim of the planned research project is to exploit the lightweight potential of honeycomb core sandwich structures in vehicle and equipment construction by increasing the paper content. This should also significantly improve the sustainability and ecology of the components and will be demonstrated using roof structures. The tasks formulated in the planned project can be summarized as follows:

Preventing the marking of honeycomb structures on sheet metal or plastic parts without the need for additional plastics
Simplification of cost-intensive production processes with high cycle times in the manufacture of composite components based on paper honeycomb structures by means of novel and innovative procedures
Minimization of the weight per unit area of lightweight composites in vehicle construction
Possibility of producing flat and curved structural components