As part of the research project a completely new construction method for the manufacture of lightweight panels was developed. The first panel structures realized with this technology can already measure up to the state-of-the-art, as can be seen in a comparison with aramid honeycomb panels that are standard materials in the aerospace industry. Problematic material behavior in the use of the honeycombs, such as delamination of the panel layers, can be completely prevented by application of an integral fiber-based structure within the new panels. Local load peaks, however, do not cause any catastrophic failure of the panel core and are transferred to the overall structure via the elastic material behavior of the pile yarns. Thus, the developed structures can be utilized in a wide range of applications in the future, e.g. structural components in vehicle construction, containment structures for energy storage systems in electric vehicles, and box and radio superstructures for commercial and emergency vehicles. They can also be applied for ceiling structures in shipbuilding and rail vehicles, as well as for partition systems and floor panels in building equipment, in mobile multi-purpose structures and in machine and plant construction for enclosures with a protective function and as lightweight components in guide, conveyor and distribution systems. A final economic analysis shows the considerable potential of the developed lightweight panels. The manufacturing costs are estimated to be only 25 to 50 of the reference aramid-based honeycomb panels. Thus, there is a substantial and steadily growing market potential and, therefore, a high benefit for the new products to be developed by the textile industry, which are mainly SMEs.
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