Lightweight Rear-Seat Shell in Composite Design

By on September 28, 2019 in IN THE NEWS

The Tepex continuous-fiber-reinforced composites from specialty chemicals company LANXESS is being used in the Audi A8. This sedan is offered with two electrically adjustable individual rear seats, the shells of which have been developed by Faurecia Automotive Seating and are manufactured using the hybrid molding process. The polyamide-6-based Tepex dynalite 102 RG600(2)/47% is used for this purpose. The short-glass-fiber-reinforced Durethan BKV30H2.0 polyamide 6, also from LANXESS, is used as an over-molded material.

“The reason that our composite material was chosen for this structure was the fact that it is around 45 percent lighter than a comparable metal design but can also be produced cost-effectively, thanks to the high degree of functional integration. It can also withstand the high mechanical loads in a crash,” explained Henrik Plaggenborg, head of Tepex Automotive at the LANXESS High Performance Materials (HPM) business unit. The system supplier of the fully assembled rear seat system is the automotive seating business division at Faurecia in Stadthagen, Germany.

This is a cost-effective process. “In the hybrid molding process . . . a ready-to-install component is created in a single process step. The pre-contoured and heated semi-finished composite product is formed directly in the injection molding tool for this purpose, and equipped with numerous functions by means of injection molding. This simplifies subsequent assembly and leads to considerable savings in production costs,” commented Tilmann Sontag, project manager at the Tepex Automotive group of HPM.