faurecia interior systems less is more brett schnur innovation project leader
TRANSCRIPT
Faurecia Interior SystemsLess is More
Brett SchnurInnovation Project Leader
AGENDA
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CCB: Cross Car Beam
NAFILean Natural Fiber for Lean Design
Injection
Lignolite+ & NFPP+
Cross Car Beam
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COMMON WEIGHT & PERCENT OF VEHICLE INTERIORRepresenting 33% of the instrument panel weight, the CCB is the heaviest component.
CROSS CAR BEAM - The Key Figures
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Faurecia is approaching the cross-beam challenge from three directions that are driven by a “Less is More” perspective.
CROSS CAR BEAM - Innovation
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CROSS CAR BEAM - Faurecia’s Plug & Play
The Plug & Play Steel CBB offers a 5% reduction in weight.
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ABOUT THE PLUG & PLAY Variable thickness (from 1 to 2 mm) Variable diameter (from Ø40 to Ø80)
Variable Inertia
CROSS CAR BEAM - Faurecia’s Plug & Play
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CROSS CAR BEAM - Faurecia’s Hybrid CCB
The Hybrid CCB offers weight savings of up to 20%.
Sheet Molding Compound (SMC)
Steel from Plug & Play Technology
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The Composite CCB leads to weight savings of more than 40%.
CROSS CAR BEAM - Faurecia’s Composite CCB
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WEIGHT SAVINGS
CROSS CAR BEAM - Summary
Full steel CCB assembly using Cold Metal Transfer Welding
PLUG & PLAY CCB
HYBRID CCB
COMPOSITE CCB
Combines 3D SMC attachment brackets to Plug & Play steel technologies
Combines multiple technologies for maximum weight savings
Up to -5%
Up to -20%
Minimum -40%
2015
2016
2018
NAFILean
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AUTOMOTIVE PERFORMANCE MATERIALS
Natural fiber specialist headquartered in France Automotive injection
molding expert
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ABOUT NAFILEAN Polypropylene +20% natural fiber compound to
substitute for PE-MD20 and ABS Injection molding of covered DP trim parts, IP top
cover, defrost and closure ducts
COMPETITIVE ADVANTAGES Lightweight concept: up to -25% for door panel and -
20% for instrument panel, depending on architecture Green material with better environmental impact /
CO2 balance: -20 to -25% Life Cycle Assessment
NAFILean
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Natural Fibers for Lean Design Injection
DEVELOPMENT OF FAURECIA’S PP + NATURAL FIBERS COMPOUND
In production on Peugeot 308 door panel
Validated at multiple OEMs
One patent
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DOOR PANEL
NAFILean - Validated Parts
WEIGHT SAVED
25%
2-2.5mm thickTOP ROLLS
INSTRUMENT PANEL
BOLSTER / INSERT WEIGHT SAVED2-2.5mm thick
25%
DOOR PANEL CARRIERS2-2.5mm thick
WEIGHT SAVED12.5%Direct drop in
TOP PAD2-3.5mm thick
WEIGHT SAVED 20%
Density & thickness
DUCTS2mm thick
WEIGHT SAVED 20-25%
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PROCESS Injection Back injection Weakening by laser (air bag
function) TPO Thermo-covering Foam in place Vibration and U.S. Welding Fastening
Adheres to Design Standards
PRODUCT VALIDATION Dimensional behavior on instrument panel Sun load 120°C for 500hrs Climatic aging Air bag deployment Head impact NVH – CAE Comparison Foaming Side impact Repeated load durability
Often Better Than Production
NAFILean - Interior Validation
Compression-Molded Mat Technologies
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NATURAL FIBER MAT
TWO TYPES OF IMPROVED LIGHTWEIGHT COMPRESSION-MOLDED MATERIALS
LignoLite+ NFPP+ (Natural Fiber
Polypropylene)
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ABOUT LIGNOLITE+ Lightweight door panel carriers made from
Wood Fiber Composites (WFC)
Based on hot press technology
Made up of 85% natural fibers, bio-based material, green and renewable material
Contributes to weight reduction—up to 25% savings vs. currently used lightweight solutions
Up to 45% savings vs. injected carriers, resulting in CO2 reduction and integration of renewable materials
LIGNOLITE+ Door Panel Application
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Resin 1 Resin 2 Resin 3 Wood FibersBonding Fiber 1 Bonding Fiber 2 Other Fibers Wax
Lignotock
Lignotock+
Lignoflex ECO
Lignoprop
LignoLite
LignoLite+
Resin 3 Wood fibers Other fibers
LIGNOLITE+ Tailored to Your Application
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NFPP+ Door Panel Application
Common industrial mat weight =
1450 gsm
1250gsm mat available
Weight savings of 14% (vs. common
mat)
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CCB:Cross Car Beam
NAFILean Natural Fiber for Lean Design
Injection
Lignolite+ & NFPP+
Validated to Multiple OEM Specs Weight Savings : DP = Up to 25%
IP = Up to 20%
Weight Savings of 45% vs. Standard Injection Materials
Weight Savings : up to 40%
CONCLUSION