The Audi A8 is equipped with two electrically adjustable, independent rear seats. The housing is developed by Faurecia Automotive Seats and manufactured using a composite molding process. It uses polyamide-6 based TEPEX Dynalite 102-RG600 (2) / 47. %, The short glass fiber reinforced Durethan BKV30H2.0 polyamide 6 used in overmolding is also from LANXESS.
High crash stability
"The customer chose our composite material for this structure because it was about 45% lighter than the metal design. Thanks to the high level of functional integration, it enables cost-effective and efficient production and can withstand high mechanical loads in the event of a collision," Explained Henrik Plaggenborg, head of TEPEX Automotive at LANXESS Performance Materials (HPM).
The system supplier for fully assembled rear seat systems is Faurecia's Automotive Seating business unit in Stuttgart, Germany.
Low cost, one-step molding process
Until now, similar seats have been mainly made of metal shells and screwed to the base. Manufacturing metal enclosures is time consuming because they consist of many separate parts that must be welded together several times before they can be joined together.
"In contrast, in the composite molding process, ready-to-install components can be made in just one step. This allows heating and manufacturing of preformed composite products directly in the injection mold and using injection molding to make These products have multiple functions. This simplifies subsequent assembly and significantly reduces production costs, "comments Sontag, project manager of the HP TEPEX automotive group.
In addition to the ribs, duct grooves to hold the valve seat cover in place, as well as many clamps and guides (such as for seat ventilation and cable clamps) are integrated into the assembly. The clip attached to the seat shell is also inserted directly. "Clips can be assembled quickly and easily without the use of screws and then disassembled again for repair. These clips are very stable and meet all relevant safety requirements," Sontag added.
Comprehensive HiAnt customer service for component development
As part of its HiAnt customer service, LANXESS has provided full support to project partners in the development of seat shells and complete rear seat systems.
For example, HPM identified material data for composite and overmolded materials required for Faurecia structural simulations in order to calculate the mechanical resilience of safety components.
In addition, several strategies for the accurate and repeatable formation of semi-finished composite products were analyzed in the overhang simulation. These strategies are incorporated into the optimization recommendations of design tools and processes. "For example, we recommend using special clamps to hold the plasticized composite sheet in an injection mold." Sontag said.
Wide range of applications
TEPEX is developed and produced by Bond-Laminates Ltd., a LANXESS subsidiary headquartered in Brilon, Germany. The value of TEPEX dynalite has been proven in large-scale applications of structural lightweight automotive designs.
For example, it is used for mass production of front ends, brake pedals, underbody components, reinforcement inserts for removable body parts, and brackets for doors and electronic modules.
LANXESS expects this composite material to be used in the future to make backrests and armrests, as well as seat shells for new highly sophisticated seat systems for autonomous driving.
Plaggenborg said, "We are considering the design of freely rotatable, rotatable or detachable seats that are not only lightweight but also meet all crash requirements and are equipped with many integrated features such as seat belts, infotainment and comfort systems "In addition, this lightweight material can be used to make comfortable seats for buses, premium buses and family buses.