Body + Interior | Components for car comfort

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Details: Released: 20.09.2020; Last updated: 23.09.2024; Hits: 6861

The modern vehicleBody relies on lightweight materials such as aluminum and high-strength steel to reduce weight and at the same time increase safety standards. These developments contribute significantly to increasing efficiency and enable better driving dynamics. In Interior The focus is on integrating smart technologies and high-quality materials that improve comfort, aesthetics and user-friendliness.

Covestro car cockpit interior

Content

Three-dimensional lighting concepts in the car interior
Backlash-free multi-link hinges with self-calibrating plain bearings
Volkswagen integrates ChatGPT into current models
DC motor as a multi-talent for modern vehicles
Lightweight headrest with organic sheet for the child car seat
Reinvention of the display for the car cockpit of the future
Intelligent headlights in twelve global versions
Telescopic rails for the stable trunk full extension
Magnetic sensors for sunroof, exhaust gas recirculation and airbag
Brushes against marten bites and as versatile helpers in the automobile

Three-dimensional lighting concepts in the car interior

KURZ car interior 23.09.2024 | How material-saving and flexible lighting concepts can be implemented in the automotive sector is shown Leonard Short on Fakuma 2024The expert for decorative and functional surfaces presents together with AMS Osram For the first time, a method for energy-efficient lighting of decorated panels in the automotive sector, with which customer-specific lighting effects can be staged in three dimensions.

The In-mold decoration (IMD) and the Functional Foil Bonding (FFB) form the basis for the technology. The IMD process enables plastic parts to be formed and finished directly in one step using injection molding, which makes the production process extremely efficient. The FFB process also enables mini LEDs to be placed on films with high precision and in an automated manner. As a post-mold process, FFB is only used on defect-free components, which significantly reduces material waste.

In combination with the Aliyostm Technology Osram's mini LEDs can be easily mounted on refined surfaces in interior design. This allows for flat, homogeneous components and an aesthetically pleasing look.

Mini LEDs enhance interior design

Aliystm technology enables the precise arrangement of Mini LEDs on transparent metal cables, which allows individual shapes and animation effects to be created in the interior. This makes it possible to implement everything from standard lighting functions to unique control elements with a shy-tech effect. This combination combines functionality with a sophisticated design that is intuitive to use and visually impressive. The technology allows segmented lighting design and benefits from the high efficiency through the integration of the advanced Kurz processes.

The process eliminates the need to install a separate light module, which results in a significantly flatter component design. In-mold decoration (IMD) also allows day-night designs to be implemented efficiently without additional work steps. The method is suitable for components with a deformation of up to 2,5 D.

Backlash-free multi-link hinges with self-calibrating plain bearings

12.04.2023/XNUMX/XNUMX | The production of multi-joint hinges for spoiler kinematics and top can be expensive. With a Igus Plain bearings made of tribologically optimized plastic make an economical and technically superior design possible. The new Iglidur F300 is even electrically conductive and can calibrate itself using the cathodic dip painting (KTL) process.

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Volkswagen integrates ChatGPT into current models

09.01.2024 | Volkswagen is once again setting standards in the automotive industry. With a world Premiere The car manufacturer entered the race for the most fascinating new technical developments from car manufacturers at the CES 2024 electronics trade fair in Las Vegas: Volkswagen will be integrating from now on Chat GPT in current models. This pulls it Artificial intelligence into the automobile.

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DC motor as a multi-talent for modern vehicles

31.03.2022 | The brushless DC motor is a key component for many vehicle applications. The motor, which is only about 5 cm in size, can be found EC-Motor in drive to steering. Schaeffler develops and manufactures DC motors in Bühl with immediate effect. The automotive supplier is thus entering a growing field of business.

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Lightweight headrest with organic sheet for the child car seat

Uni Chemnitz Headrest Interior 20.09.2020 | Scientists at the University of Applied Sciences have developed a 26% lighter headrest for child car seats. TU Chemnitz Developed together with Avionaut and Polycomb. In addition, they have developed the technical basics to manufacture the headrest in a way that conserves resources.

The child seat in the car should meet three criteria in particular: high safety, low weight and easy to handle. Researchers at the Chair of Lightweight Structures and Plastics Processing SLK of the Technical University of Chemnitz have taken on these three points. Together with the Thuringian plastics company Polycomb and the Polish child seat manufacturer Avionaut, they designed an ultra-light headrest in a research collaboration. This also offers better crash performance and has been optimized with regard to component production.

Organic sheet reinforces the headrest

As part of the basic research, a formed organic sheet was developed for local stiffening of the headrests. "Organic sheets are fiber fabrics that are enclosed in a plastic matrix. They are characterized by their particular stiffness, strength and low weight. They are therefore very suitable for lightweight construction, such as in automobile or aircraft construction," explains Norbert Schramm, Research Associate at the SLK Professorship.

Polycomb was responsible for injection molding in the further development. This is where the preform, i.e. the blank of the component being manufactured, was manufactured. This also includes the support plate for the headrests, which is used for integration into the back of the seat.

Tracking system for child seats based on RFID and TBEN-S

Airplane As the client, the company specified the appropriate materials and carried out the foaming of the headrest. This was done using foam beads made of thermoplastic Plastics thanks to the energy-saving particle-foam composite injection molding. In addition, one took over the completion of a demonstrator here.

The new headrest from the child's car seat Weight class from 9 to 36 kg is now 26% lighter than a comparable standard component. The technology development was funded by the German Association of Industrial Research Associations (AiF) and the Federal Ministry for Economic Affairs and Energy (BMW i) as part of the Central Innovation Program for SMEs (ZIM).

Particle foam composite injection molding

In particle foam composite injection molding PSVG it is a coupled process. First, an insert made from an organic sheet is formed in an injection molding tool with a turning plate and back-injected with a short-glass reinforced plastic matrix. The resulting preform is then turned into a second tool on the machine and foamed over.

IR and UV emitters for high-quality car interiors

Because there is no need for intermediate storage, cooling or reheating, this manufacturing process is special ressourcenschonendThe heat energy introduced in the first step can be used in the second step. The basic idea of bivalent resource efficiency has been applied here. It corresponds to the mission statement of the Merge Cluster of Excellence at Chemnitz University of Technology. Merge has set itself the goal of saving energy in use and production. The additional savings in the manufacturing process are achieved by the component coming out of the tool ready for installation.

Transfer of the headrest to production

The transfer of the manufacturing process of headrests for children’s car seats in one step and the component design offer several advantages for manufacturers and users. Assembly steps and energy in production can be saved with PSVG. The components of the end product hold together better. The significantly reduced weight leads to further Energy savings while transporting. Handling when installing and removing the child seat is made easier.

Financial savings gained from the economy of the headrest can be passed on to the consumer. The transfer of the results of the research project for the production of the ultra-light headrest into practice is now the responsibility of the child car seat manufacturer.

Reinvention of the display for the car cockpit of the future

Covestro car cockpit interior 08.06.2020/XNUMX/XNUMX | in the Car of the future displays and display instruments in Vehicle Dashboard take on a whole new role. They become infotainment systems that network occupants with the outside world and offer information or entertainment. The car interior will therefore be mobile and multifunctional. Covestro has now designed a display concept for the future car cockpit.

We will Car interior increasingly used as living and working space. The driver of innovation in this development is the interaction between people, cars and the environment. The main component of this interaction is the display. The demands on functionality and design are constantly growing.

To see this challenge as an opportunity, new concepts in display design and good integration in the car cockpit are required. Together with an industrial partner, Covestro developed a display concept. It should meet the increased requirements in terms of optical quality, resistance and design. The seamless interface between people and cars resulting from this collaboration is the largest to date three-dimensional oled display.

Display with a curved surface and a clear picture

For the display for the car cockpit, two Covestro Materials used: the polycarbonate Makrolon Ai and the polycarbonate film Makrofol. Both are thermoplastic products. They can be processed into geometrically challenging components in good quality with a long service life. The high optical purity of the polymers ensures bright, clear colors of the OLED displays without image distortion through the curved surfaces.

Self-driving cars from the perspective of an automotive supplier

In the production of these highly complex components, Covestro draws on its many years of experience in process development. A sophisticated combination of manufacturing technologies ensures the surface design and durability. The surface, shape, appearance and feel of the component can be individually adapted to customer requirements.

Intelligent headlights in twelve global versions

Headlights for global requirements from Hella 11.03.2020 | Not all lights are created equal: The way headlights are allowed to illuminate the road varies from region to region. In the USA, for example, the low beam of a Automobiles both lanes illuminate further into the distance. In the EU, however, the focus is more on illuminating one's own lane and minimizing glare for other road users. Hella is now introducing a spotlight that covers global requirements.

In order to ensure the specified light distribution, different optical systems have to be developed and manufactured for vehicle headlights depending on the area of application. Taking into account right-hand and left-hand traffic, up to twelve technically different headlights may be required for a worldwide vehicle model.

With the new world of spotlights from Hella for a global presence Premium manufacturer this variety of variants becomes superfluous. In this case, the light is adjusted using software-controlled SSL 100 light modules. The digital control can activate each pixel individually. The entire light distribution can reflect the respective regional regulations. For example, the identical headlamp illuminates a traffic circle in right-hand or left-hand traffic and prevents oncoming traffic from being dazzled.

Implementing lighting functions through software

Hella is working consistently on the Digitization of light and in perspective, the entire range of LED headlights from 100 light pixels to high-resolution SSL | Digitally cover HD technologies with tens of thousands of light pixels. “With our new headlight models, we have a technical basis to implement all light functions using software and to adapt them flexibly to regional requirements.

Dispense liquid sealant directly onto automotive components

This also includes additional functions like that glare-free high beam or projected orientation lines on the road, ”says Dr. Michael Kleinkes, responsible for global lighting technology development at Hella. "This enables us to further accelerate our development process and reduce the expenses required for development, production and logistics of regional spotlights."

With the SSL 100 module, Hella has the intelligent lighting control now fully implemented for the first time for a global automobile manufacturer. Series production of the headlights will begin in the middle of the year at the Mexican plant in Irapuato and at the end of the year at the plant in Jiaxing, China.

Telescopic rails for the stable trunk full extension

20.10.2017/2/XNUMX | Basecab XNUMXmove is a Full extension for trunk of the Land Rover Discovery, which uses its entire extension length even when the rear seat is folded down. It retains the normal trunk size and also offers full through-loading capability. This is made possible thanks to the high rigidity and high load-bearing capacity of the "Hegra Rail" telescopic rails from Rollon.

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Magnetic sensors for sunroof, exhaust gas recirculation and airbag

25.10.2016 | The magnetic sensors of MS Schramberg is used in various applications, particularly in the automotive industry. Here, magnetic field sensors ensure the smooth functioning of airbags, engine controls or anti-lock braking systems, for example. For the area of steeringangle sensorThe company is also presenting measuring gears with integrated magnets for backlash-free gearing.

The manufacturer developed this component together with a customer. It consists of two individual gears that are elastically connected via a spring. The production of the gears including the integrated magnets, the manufacture of the spring and the assembly of the complete Gear takes place on a fully automatic system designed by the magnet specialist.

The exhibits also include Sensor magnet rings (Image). These are used, among other things, to measure speed and angle of rotation. Until now, all sensor magnets were initially sprayed onto carrier bushings made of metal or plastic due to their high brittleness.

This component was then installed at the customer’s Motor shaft pressed on. Thanks to a new, more flexible magnet compound with better properties in terms of elongation and tensile strength, the carrier bushings are now no longer required.

Brushes against marten bites and as versatile helpers in the automobile

06.01.2012 | Win in the Automotive category Technical brushes increasingly important: In the cars themselves, Mink Fiber solutions are used as privacy screens, dirt seals, to cover the convertible top mechanism or as safety accessories against marten bites. In automotive production, the versatile brushes have also become irreplaceable helpers in many areas, as this article shows.

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Source: This article is based on information from the following companies: AMS Osram, Covestro, Hella, Igus, Leonard Kurz, Mink, MS Schramberg, Rollon, Schaeffler, TU Chemnitz, Volkswagen.