Altair, a Michigan-based global technology company, and the Center for Automotive Research (CAR) nominated Marelli’s polyurethane foam for interior products for the 2023
Altair Enlighten in the Future of Lightweighting category
Award winner. Altair is a global leader in computing science and artificial intelligence (AI), providing software and cloud solutions in simulation, high performance computing (HPC), data analytics and artificial intelligence.
Marelli has developed a new lightweight polyurethane foam that can be used in all foam-in-place (FIP) applications, especially for main fascias. This achievement was jointly developed with its materials partner Covestro.
40% weight reduction
Compared to currently used foams, the new foam is 40% lighter with new tooling (8% lighter with existing tooling); 50% thinner foam to support aesthetics; lower raw material costs 20%. Consistent with the industry’s continued focus on sustainability and environmentally friendly materials, the new foam also contributes by reducing the amount of material used per part, reducing density and reducing VOCs by 80 percent
(VOC) to reduce the environmental impact of automobile production.
While delivering environmental benefits, this lightweight foam also meets or exceeds customer demands for a high-quality feel and appearance of interiors. Foam-in-place (FIP) technology is a staple in automotive interiors, effectively achieving the soft-touch feel required for major contact surface components such as main instrument panels, door panels and center console armrests.
Solvay’s Ajedium PEEK slot liner won the runner-up
Solvay Specialty Polymers’ Ajedium PEEK slot liner was runner-up in the “Future Lightweight” category. Its Ajedium
The PEEK slot liners reduce the weight of the battery pack by 12 kg (36.4 lbs) and the weight of the motor by 4 kg (8.8 lbs). In addition, because PEEK tank liners can be inserted through existing equipment, high-power dust collection equipment or climate-controlled storage are not required to prevent moisture absorption, thereby reducing energy consumption.
As electric vehicle manufacturers are increasing system voltages from 400 volts to 800 volts or more, traditional paper-laminated slot liners are no longer up to the challenge of this trend. Brian, Marketing Director, Solvay
Baleno pointed out: “In a comprehensive simulation test, Ajedium
PEEK film has proven its outstanding properties to improve the thermal, electrical and mechanical performance of slot liners while enabling thinner secondary insulation and providing a more sustainable single material solution. ”
Ajedium
PEEK’s excellent electrical insulation and heat dissipation properties also improve thermal management efficiency, allowing designers to reduce the size of aluminum castings and create more sustainable electric motors with less energy and material consumption.
In addition, PEEK film is suitable for automatic transmission fluid (ATF)
Has excellent chemical resistance and also has good adhesion to clear coats. It also eliminates the need for dust extraction equipment and climate-controlled storage, reducing energy costs and improving workspace conditions.
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