Production process adapted design of thermoplastic-compatible piezoceramic modules

Fibre-reinforced polymers with thermoplastic matrix systems are suitable for a wide range of applications in the field of function-integrative lightweight structures ready for series production. The development of functional elements which are tailored to processes is therefore of increasingly significant importance. The thermoplastic-compatible piezoceramic modules under development are suitable for adhesive-free integration into fibre-reinforced thermoplastic structures using a welding process which is intrinsic to the manufacturing process. The continuous refinement of the novel module design and the corresponding manufacturing process (which is based on hot-pressing technology) is supported by the development of tailored coupled and physical nonlinear simulation models which facilitate module design and the analysis of functionality in terms of interactions between technical and technological parameters. Special attention is given to the definition of precise, function-specific manufacturing tolerances as well as the residual stresses caused by the various thermal expansion coefficients of the module components and the use thereof as a means of enhancing module performance.