1 Technology Highlights

Transcription

Press Kit
1 Technology Highlights
2011 Frankfurt Motor Show
Contents
Automotive Seating.......................................................... 3
Complete seats
New generation seat mechanisms
Seat structures
Mechatronics
Comfort systems
Trim systems
Interior Systems.............................................................. 8
Decorated parts
Door panels
Acoustics
Green & lightweight
Emissions Control Technologies..................................... 11
Faurecia ASDS
BMW M3 complete exhaust line
Complete compact exhaust system
Turbo-manifold and close-coupled converter
Induction brazing
Hydroforming
Audi Q7 liquid SCR emissions control line
Automotive Exteriors....................................................... 13
Bumpers core business
Complete product range
Notes................................................................................ 16
About Faurecia................................................................. 19
Contacts........................................................................... 19
Automotive Seating
Complete seats
World number one in seat frames and mechanisms, and number three in complete seat systems, Faurecia unveils
two seat prototypes in Frankfurt that are bound to turn heads among industry professionals and the general public:
«Performance Seat» and «Premium Seat» both reflect breakthrough technology buoyed by stunning design.
Faurecia Automotive Seating recently caused a sensation with SmartFit™, an application for smartphones that
allows passengers to use their mobile device to identify and activate the most ergonomic settings based on their
physical profile. The world’s sixth-largest automotive equipment supplier has now taken things even further with
its Performance Seat and Premium Seat solutions—two prototypes that draw on the cream of seat technology and
design from Faurecia experts. Faurecia Design Director Andreas Wlasak: «These two prototypes reflect a daring
creative departure in which the design is used to showcase performance, perceived quality and technology; not
hide it.»
Performance Seat
Performance Seat targets entry-level to mid-range
vehicles in the European and North American
markets. Drawing on approaches used in sportswear
and fashion, it uses design as a central feature to
convey the concept of performance.
The seat is made even lighter through the use of
plastic components, which literally cover the whole
seat (including plastic seatback and plastic cushion
module). Compared with conventional seat systems,
Performance Seat solutions represent a weight saving
of some 20%. The innovation also provides a more
spacious interior.
Performance Seat goes back to basics, turning
core components into fully fledged style features:
the seat structure is visible, incorporating an active
suspension system; the cover carving offers a whole
range of textile customization options. «We wanted to
optimize every aspect of seat functionality.
Our goal was to incorporate as many
additional features as possible into
the seat structure itself,» explains Mr
Wlasak. Each seat also has its own
audio module, allowing individual
occupants to create their own
comfort zone.
Performance Seat uses design
features to put technology
firmly center stage,
with Faurecia
innovations clearly in
the spotlight.
Premium Seat
Premium Seat is the second hallmark of
Faurecia’s campaign to reinvent automotive
seating, and is designed for the premium
market. Andreas Wlasak: «Our engineers
and
designers
drew
inspiration
from the world of luxury watches:
flawless detail, use of cutting-edge
technology and reliability are three
concepts specific to the luxury
industry that also reflect
Faurecia values.»
Technology (multimedia functionality,
speakers built into
headsets and welcome
lighting), finishing quality (highprecision cut & sew, dimpled leather, metallic finish
and wood paneling), and comfort (adjustment features and thermal comfort) are the three watchwords
of Premium Seat solutions.
Echoing creations from the workshops of the finest
watchmakers, Premium Seat technology turns
Faurecia Technology Highlights
3
SmartFit™ reduces seat complexity by optimizing the
user interface to the traditional seat electronics, using
a device that occupants bring into their vehicles every
day. Moreover, eliminating redundant components is
an effective approach to reducing vehicle mass and
chemical-based materials.
ventilation components into decorative parts, notably
through clever use of dimpled leather. Air vents are
positioned all around the seat, thereby enhancing
overall air conditioning. The innovation also marks
a world first with the use of shagreen in automotive
seating. The firm, flexible covering—commonly used
by cabinetmakers and leatherworkers—further
enhances the seat’s premium feel, making it a jewel
in the interior crown.
Plastic, wood and aluminum come together to create
a resolutely high-end seat. Here, Faurecia displays the
use of Ligneos technology, which makes it possible
to work in 3D with large sheets of wood (mainly oak
and maple) to make them lighter and more flexible,
offering the benefits of hand-made craftsmanship on
an industrial scale. The approach also conveys the
true beauty of wood trim, with the option to use five
species of real wood.
The back of the headrest incorporates a complete
multimedia setup (screen, internet connectivity, etc.),
providing a comprehensive set of controls in a custom
environment. The side of the seat also features blue
welcome lighting, providing the perfect backdrop for
the on-board technology.
SmartFit™ phone-activated seat
adjustment system
Based on the acclaimed Audi A8 premium seats,
Faurecia has developed a new concept for automated
seat positioning that takes the guesswork out of
properly adjusting seats. SmartFit™ is an application
for smartphones that automatically adjusts the
vehicle’s seats to conform to the healthiest position for
each occupant, controlling the seat wirelessly.
In addition to its environmentally-friendly attributes,
SmartFit™ supports healthy posture for drivers.
Globally, people are increasingly prioritizing a healthy
lifestyle. SmartFit™ supports the consumer’s desire
for both improved wellness and mobile connectivity
by creating a seat-tailoring system designed by
ergonomic experts. It improves overall comfort, thereby
reducing potential distractions that might otherwise
result from drivers’ repeatedly readjusting their seat to
find a comfortable position. Never before has a seat
provided this level of guided adjustability that ensures
occupants take full advantage of advanced comfort
systems. As a result, automakers that incorporate
SmartFit™ into their vehicles may enjoy considerably
improved customer satisfaction scores relating to seat
comfort. No longer do consumers find themselves
confused by a multiplicity of seat controls; nor do they
need to struggle as they drive to determine the best
adjustment for their body. SmartFit™ adjusts seats to
the best fit automatically.
Faurecia’s integration of Hoerbiger’s seat comfort
segment, which specializes in the development of
leading-edge pneumatic seat comfort systems,
allows for a wide variety of comfort functions, such as
massage, shoulder, lumbar, lateral and thigh support.
Over time, lighter and thinner pneumatic systems are
expected to substitute for existing electro-mechanical
systems across vehicle segments. Obviously,
SmartFit™ will greatly benefit from the integration
of pneumatic systems, largely thanks to easier seat
comfort adjustments.
Faurecia foresees strong interest in the SmartFit™
concept and anticipates that it will be ready for vehicles
in model year 2014 or 2015.
SmartFit™ initially guides the user through an easyto-follow process for creating a digital model of his or
her body. This virtual model is combined with advanced
anthropomorphic data to calculate the perfect seat
settings. This tailored fit then is sent wirelessly from
the cloud to the phone to the seat, which automatically
adjusts itself. Individually tailored profiles can be
generated for each occupant and stored in seat
memory.
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New generation seat mechanisms
Nano height adjuster
RD7X discontinuous recliner
RC7X continuous recliner
These three new generations of Faurecia seat
mechanisms, currently under development,
are suitable for vehicles from segments A to F,
focus on weight and packaging reduction. These
mechanisms have a high dynamic breaking torque,
are light weight (up to 35% versus current products)
and more compact (up to 18% in diameter and up
to 25% in thickness). They offer weight savings of
up to 300g per seat and better perceived quality and
a smoother operation. Faurecia will manufacture
these mechanisms from 2012.
Ultima Seat Tracks
The Faurecia Ultima seat tracks represent the new
generation of high performance seat tracks, specially
designed for high-end and premium vehicles. They
exist in manual and low-noise powered versions for
3- and 5-door vehicles. Thanks to the use ultra high
strength steel, proprietary to Faurecia, it has been
possible to enhance energy dissipation in the case
of a crash by up to +20%, versus current products.
In all, the Ultima tracks provide best-in-class safety,
lightweight and perceived quality. Faurecia will start
manufacturing these tracks from 2012.
5
Seat structures
Composite backrest
A plastic front seat backrest made of high-strength
composite material, enabling design freedom on seat
backrest for new premium interior styling.
In partnership with BASF, Faurecia has developed an
ingenious composite seatback that creates an all-new
aesthetic and eliminates conventional metal frames,
heavy foam and trim covers in favor of materials that
produce a lighter, thinner and cleaner seatback. Over
the past three years, BASF has focused on enhancing
the material’s scientific performance aspect, while
Faurecia has designed, validated and integrated the
seatback system and architecture into a new firstrow seating concept for the industry. The composite
seatback is ready to make a significant difference
inside vehicles that will be launched in the coming
years.
for novel shapes and accessories to be added for the
comfort of front seat occupants and the convenience
of second-row passengers. This seatback currently
is in advanced development with Asian and European
automakers and has also seen significant interest
from North American manufacturers who are looking
to benefit from its thin and lighter-weight structure.
In preproduction programs, Faurecia is furthering
the technological maturity and integration of the
composite seatback by incorporating it into the new
generation of seating systems. Consumers could
begin enjoying the benefits of the composite seatback
on 2014 vehicle models.
Mechatronics
E-pump
Traditionally, seat height adjustment was performed
manually; however this function is now ever more
performed electrically. For this purpose, Faurecia
has developed the E-pump, a powered “seat pump”
for seat height adjustment incl. mechatronics for
the best postural adjustment in a lighter and more
compact part. The lightweight development has
enabled to save 25% weight for this function versus
traditional linear actuators. Also, the global packaging
has been reduced both in diameter (-14%) and length
(-30%) versus existing 2 pole motors. Furthermore,
compatible with Faurecia’s Nano seat mechanism
(see above), E-pump specifically targeted at C to
E segment vehicles, is expected to go into series
production later this year.
The combined first-row composite seatbacks:
• Weigh almost 20% less than conventional seatbacks,
reducing CO2 emissions over the life of the vehicle by
an estimated 100 kilograms;
• Are 15% thinner than the industry’s thinnest seats,
leading to 10 liters of additional interior cabin volume.
The lighter weight can yield improved fuel
performance for internal combustion, hybrid and
all-electric vehicles; and less fuel consumption
means fewer emissions of greenhouse gases. At
the same time, the significantly thinner seatbacks
allow designers either to provide more leg room to
the second-row occupants or to shorten the overall
length of the vehicle, thereby further reducing its
total weight. The seatback is a technically mature
system that has been fully validated for reliability,
safety and comfort. Designers now have entirely
new opportunities to customize and adapt seatbacks
in vehicles. Since they are created with injection
molding systems, the composite seatbacks allow
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Comfort systems
MHH (Multi Horizontal Hardness)
A new foam pad, i.e. with reduced cushion height
providing the same comfort level as a standard foam
pad, particularly for low-roof vehicles.
This new foam for seat cushion has been designed
for both front and rear seats, particularly for low-roof
vehicles. It replaces the cut foam gluing process with a
“light” compression process while offering enhanced
comfort levels and also offers a new comfort approach
for seat bolsters. The process consists in spraying
several polyurethane formulas in two-steps before
final compression. Not only is the foam thinner, it is
also up to 20% lighter than traditional foam pads.
Pneumatic Systems
For ultimate driver and passenger(s) comfort: the
ultimate solution for premium best-in-class postural
comfort.
Faurecia pneumatic seat systems exist is several
configurations from 4 to 8-way, offering the complete
range of lumbar support and comfort adjustments as
well as massage functions for backrest width, cushion
width, cushion length and shoulder adjustment. The
system uses a series of highly discrete, lightweight
(< 1kg/seat) TPU [thermoplastic polyurethane]
inflatable bladders, which can be individually
controlled. These variants enable to propose the most
advanced premium seating features for top of the
range comfort and back pain relief offering exclusive
comfort features.
At the IAA this year, Faurecia’s pneumatic seating
systems can be found on the following newly
introduced vehicles (standard or optional): Audi A6
Avant and Mercedes-Benz M-Class.
Trim systems
X-locking headrest
A 4-way front headrest with side button for user
friendly adjustment and increased safety and comfort.
With the acquisition of Hoerbiger’s Automotive
Comfort Systems activity at the end of 2010, Faurecia
has taken the lead in active seat comfort systems.
Its proven track record ranges from Audi A8 and A6,
to BMW 7 Series and Mercedes-Benz S-Class and
the new M-Class to name but a few. Pneumatic (vs.
electro-mechanical) seat comfort systems, mainly
targeted at premium vehicle segments, allow for a
wide variety of comfort functions, such as massage,
shoulder, lumbar, lateral and thigh support.
The 4-way X-locking headrest is an ideal replacement
for active or reactive headrests, offering more value for
a lighter weight. The easy unlocking is performed via
a simple side button, while the front part adjustment
range can reach up to 25 mm. For C to E segment
vehicles, this solution offers the best compromise
between comfort and safety and can also be tailored
to fit the vehicle’s styling with rear shell finish. This
headrest will go into series production in 2012.
In addition, the pneumatic systems can be adjusted
individually to the contour of the driver/passenger,
resulting in ergonomically first-class vehicle seats
using the sophisticated system. This is already the
standard in the latest high-end German “premium”
vehicles. Over time, lighter and thinner pneumatic
systems are expected to substitute existing electromechanical systems across vehicle segments.
Furthermore, the pneumatic seat systems developed
by Faurecia and the components installed in the seat
systems are covered by a comprehensive portfolio of
patents, ensuring long-term technology leadership.
7
Interior Systems
Decorated parts
Mercedes-Benz SLK IP/CC (slush IP including
center stack featuring aluminum decoration parts)
Volkswagen New Beetle IP (including interior
decoration using either high gloss paint or film.)
For this revamped icon, Faurecia has developed and
manufactures the complete instrument panel, incl.
glove box, air vents and IP deco trims (paint, film). The
so-called “Dash Pad” is a wink to the original Beetle
without being retro. In Europe this dash pad is painted
a high gloss black on the “Beetle” trim, in the car body
color in the “Design” trim, whereas the high-end “Sport”
trim features a very dynamic carbon fiber look (film). As
in the original Beetle, the new Beetle boasts an extra
glove box (the “Beetle” box) integrated into the dash pad
on the passenger side. Its lid opens upward, while the
standard glove box –situated in the lower part of the
instrument panel– opens downward.
Volkswagen New Passat IP
(including aluminum trim.)
The Instrument Panel of the Volkswagen Passat has
been developed and is manufactured by Faurecia. The
top cover skin is made of sprayed polyurethane, i.e.
without PVC, thus reducing volatile organic compounds
(VOC) emissions inside the vehicle. The top cover
structure is made of styrenics with Glass Fibers (ABS/
PC – GF13). The instrument panel structure integrates
air duct in styrenics (ABS/PC) and shot channel (in two
different versions: with/without diffuse ventilation). In
terms of decoration trim, the technology used is brushed
aluminum, signed Faurecia Angell-Demmel, or real
wood appliqué. The touch and feel of the aluminum
trims of the IP, center console and door panels convey a
particularly refined atmosphere. The overall result is a
high level of perceived quality which conveys a premiumfeel. Thanks to the integration of a soft seamless airbag
it ensures a safer airbag deployment.
Faurecia supplies the slush instrument panel for the
new Mercedes-Benz SLK, further enhancing the car’s
high-end style. The sports luxury embodied by the SLK
interior is underscored by the addition of brushedaluminum trim. This high-end material showcases
‘hand-made’ expertise and comes as standard. The
color display and entertainment features are housed in
the center of the dashboard. The top of the dash also
features an analog clock, an unusual detail that subtly
underscores the roadster’s refinement. This area of
expertise is the work of Angell-Demmel, the world’s
leading manufacturer of aluminum trim for automotive
interiors, acquired by Faurecia in January 2011. The
move reflects Faurecia’s determination to strengthen its
ties with German customers in the premium segment,
including Daimler, while enhancing its range of products
and technologies for automotive interiors.
Ford Focus complete cockpit: featuring material
harmony & decoration parts.
In designing features such as the cockpit-style
instrument panel, Faurecia has brought a number of
improvements to the compact-yet-functional car. The
integrated Reinforced Airbag Lid Foamed (RALF) concept
completely masks the airbag flap while ensuring optimal
deployment in the event of an accident. The wraparound
center console gives easy access to the key onboard
controls and displays. Drawing on the collaborative
efforts of a number of international names, the Focus is
breaking new ground in the global market, setting new
standards in driving comfort and design: the modern
feel of the car’s interior and its impressive finishing help
give occupants the feeling that they are travelling in a
premium-class sedan. Assembled at SAS (a Faurecia &
8
Continental JV) in Saarlouis (Germany), the Ford Focus
cockpit offers outstanding fit and finish, integration of
decorative trims, a harmonious blend between upper
and lower parts and invisible mechanical components
(with no visible screws). Faurecia technology has brought
the new Ford Focus to the next level in perceived quality.
Citroën DS5 door panel: a premium reference
incl. cut & sew armrest and door liner.
Door panels
Cadillac SRX door panel: a premium reference
incl. cut & sew armrest and localized foam.
For the Cadillac SRX midsize premium SUV, Faurecia
has developed the front and rear door panels. The top
roll and inserts feature a cut & sew hand wrapping
with artificial leather, the armrest, including local
foam, is made of a molded collapsible substrate hand
wrapped with polyurethane. The door panel lower
carrier is made of injection molded TPO (thermo
polyolefin), while real wood appliqué rounds up the
premium feeling. Finally, the door panel also features
a puddle light while ambient lighting is optional. With
robust yet fine materials, Faurecia offers a high level
of perceived quality and a specific attention to detail
and high-end finish. The door panels offer a soft
treatment and excellent haptic and grain quality on
the main touch surfaces, highlighted by the use of
authentic wrapping, high quality materials offering
also a quiet ride.
Contributing both to style and interior elegance, the
Citroën DS5 door panels are perfectly integrated into
the refined and attractive interior where surprise
and seduction dominate. They reflect the attention to
detail, both in the choice of material (color and trim) –
for example with the « Club » smooth full grain leather
– as well as in the fit and finish perceived quality. The
expertise and craftsmanship of Faurecia designers
and engineering teams can be seen in the attention
paid to seams and the matching cut-and-sew leather,
plastic and aluminum of the door handle. Faurecia
has been able to offer a modern interpretation of
what Premium means.
Aluminum decoration
Full range of aluminum decoration parts on a totem
presenting a variety of decorations to reach several
effects and patterns for tailored or bespoke solutions.
Acoustics
Citroën C6 package tray
The Citroën C6 premium sedan boasts a lightweight
package tray using a compression molded carrier
made out of extruded polypropylene filled with
woodstock, offering both high perceived quality and
recyclability.
9
Molded floor carpet
Green & lightweight
The structural floor developed by Faurecia replaces
steel, injected plastic or composite floors. It is made
of a twin wall Sommold glass fiber polypropylene
mat, offering high load resistance and as well as
functional integration of air ducts, storage boxes, air
grids, attachment features and acoustic insulation.
Smart fortwo IP (flax / polypropylene)
The instrument panel consists in equal proportions
of a substrate which contains compressed flax
fibers and polypropylene. It is pleasant to the touch,
particularly the fabric-covered soft surface on the
top cover, and provides weight savings of 15% when
compared to traditional solutions. Other advantages
include excellent impact / crash performance.
BioMat (100% bio-sourced composite
material)
A lightweight material that Faurecia has developed
for the rear shelf of cars has now been adapted for
flooring of multipurpose vehicles (MPVs), as well.
Sommold is a glassfiber-reinforced polypropylene
material that Faurecia has designed for package trays
that need no welded pivots for rotation. The Sommold
option reduces costs and diminishes weight by as
much as 50 percent compared to traditional materials.
Faurecia has advanced its Sommold technology to
produce a complete structural floor that can replace
heavier flooring materials in vehicle trunks and in
the second and third rows of MPVs. The new flooring
includes structural and carpeting components and
allows for the integration of air ducts between the two
sheets of the Sommold floor to cool or heat the rear
portions of the vehicle. In addition to saving as much
as 5 to 7 kg per vehicle, nearly 100% of the Sommold
floor is produced using recycled materials, and the
material offers high levels of acoustics dampening,
making it an exceptionally environmentally friendly
Faurecia product.
Over the last three years, Faurecia has been working
on the development of bio-sourced “plastic” to replace
traditional oil-based plastics used for automotive
interior parts. BioMat is the result of Faurecia’s
innovation process, now ready for commercial
deployment, first for non-visible interior parts.
10
Emissions Control Technologies
Faurecia ASDS
Anticipating ever more stringent international
emissions legislation on Nitrogen Oxide (NOx) across
all regions of the world, Faurecia, the world leader
in emissions control technologies, is presenting
the Faurecia ASDS (Ammonia Storage and Delivery
System), its breakthrough NOx reduction technology
for Diesel engines. The Faurecia ASDS is a pure
ammonia Selective Catalytic Reduction (SCR) system –
as an alternative to liquid SCR systems– which delivers
very precise amounts of ammonia to a catalyst in the
exhaust line. This step enables highly efficient removal
of NOx from Diesel engine exhaust gases for both
passenger cars and commercial vehicles. Faurecia
is confident that this technology will offer significant
advantages to automakers when meeting Euro 6,
Tier 2 Bin 5 and future Euro 7, Tier 2 Bin 2 emissions
regulations for Diesel NOx reduction. For more
information, see separate Case Study on Faurecia
ASDS.
BMW M3 Complete exhaust Line
Faurecia developed and manufactures in Augsburg,
Germany the full gasoline exhaust line for the sports
vehicle BMW M3 4.0-litre V8 engine.
The complete line consists of:
• dual fabricated manifold with a “4 in 1” geometry;
• four different catalytic converters (two in closecoupled position, two in under-floor position) with oval
section;
• hydroformed pipes (diameter 65mm) with a heat
• shield to protect surrounding components;
• transverse rear muffler with four tail pipes;
Faurecia is the exclusive supplier of the full exhaust
system (manifold / hot-end / cold-end) to this premium
sports vehicle. The line offers lower backpressure to
allow high performance of the engine at full load and
brings superior acoustics to match the customer’s
brand requirements. It also fulfills European Euro 5
emissions regulation.
Complete compact exhaust system
(for “Range Extender”)
Today, electric vehicles have limited autonomy due
to the capacity of current state-of-the-art batteries.
Therefore many electric vehicles will use a range
extender – a small and optimized internal combustion
engine - to recharge the vehicle’s batteries and improve
the overall driving range. The exhaust system for such
a range extender engine poses new challenges for
emissions control, acoustics and packaging.
Faurecia introduces its prototype range extender
exhaust system designed for a two-cylinder gasoline
engine. This consists of:
• a maniverter, or combined manifold and catalytic
converter, which collects exhaust gases and eliminates
the three main pollutants (HC, CO, NO). The catalytic
converter efficiency is enhanced thanks to its closecoupled position;
• two mufflers: a main muffler and a small resonator,
using long, ultra thin-wall pipes (0.8 mm) for efficient
low-frequency attenuation.
As an optional component, Faurecia’s EHRS (Exhaust
Heat Recovery System) can be fitted to the range
extender exhaust system. The EHRS uses waste
exhaust heat to warm up the passenger cabin and
ensure optimal engine warm-up at cold start and
hence improve fuel consumption.
Other optional equipment includes electric acoustic or
adaptive valves, which may be fitted to the system to
reduce the size of the main muffler, thereby reducing
the mass and size of the exhaust system, while
improving the overall acoustics of the vehicle.
.
11
Turbo-manifold and close-coupled converter
(for BMW 2.0 liter gasoline twin turbo engine, 245hp)
Brazing is particularly well adapted for complete
hot and cold-ends, manifolds and tailored tubes.
Faurecia has proven this technology for various
products and is already in production on: fuel
vaporizer (Ford); tailored thin-wall tubes (Audi Q7,
Mercedes-Benz S-Class and Porsche Panamera);
high-performance manifold flanges (BMW M3).
Faurecia will start production of a fully brazed coldend exhaust system in early 2012.
Hydroforming
The Faurecia lightweight air gap insulated twin scroll
manifold and close-coupled converter offers more
torque and more power, combined with lower fuel
consumption, to this state of the art engine. The twin
scroll configuration allows for the optimized combination of low-speed response and high-end power. The
fabricated manifold, 20% lighter than a cast alternative, uses hydro-formed pipes and withstands gas
temperatures of up to 980° C, allowing for high-performance driving.
Induction brazing
Faurecia Faurecia’s advanced process technologies
for exhaust products now includes induction brazing.
Brazing is a metal-joining process whereby a filler
metal is heated and distributed between two or more
close-fitting parts by capillary action. It is similar to
soldering, except the temperatures used to melt the
filler metal can go up to 1,000°C. The heating occurs
as a result of the resistance to the flow of current
induced by conductive materials when placed in a
magnetic field produced by a high frequency.
In the automotive industry, this technology is unique
for complete exhaust systems. It brings advantages
of reduced weight by enabling the use of thinner
materials (0.6mm) which cannot be joined by welding.
It also delivers higher quality, as it is spatter free
and without distortion, and better durability than a
line using welded joints
Another process technology used by Faurecia for its
exhaust business is “hydroforming”. Hydroforming
is a state-of-the-art manufacturing process, already
widely used for tubes and manifolds. The principle is
to inflate a tubular part inside a tool by a pressurized
liquid, in order to give it a pre-defined shape. This
technology is now being used by Faurecia for muffler
shells to provide a perfect underbody fit, as noncylindrical shapes can be obtained at the same cost
as cylindrical shapes. It also allows more design
freedom to make oblique inlets or outlets, and to
use variable wall thicknesses (for example 1mm at
inlet/outlet and 0.6mm in the center muffler section)
thus reducing overall mass. As a general rule this
technology is less costly than a stamped muffler of
similar internal volume. After passing all necessary
Faurecia testing phases, this technology is currently
being promoted with several major automakers.
Audi Q7 liquid SCR emissions control line
Supported by the acquisition of EMCON Technologies
and its expertise in diesel systems for passenger
cars, Faurecia has become a major supplier of
selective catalytic reduction (SCR) technology for
clean-diesel vehicles. The SCR reduces nitrogen
oxide (NOx) pollutants by using ammonia as a
reductant to convert the NOx into nitrogen, water
and carbon dioxide (CO2). Faurecia’s SCR system
can slash NOx emissions by 90% while preserving
the fuel economy and operational benefits of diesel
engines. This technology has been adopted by many
producers of cars and light trucks over the past three
years and is recognized by engine manufacturers as
the preferred diesel emissions-control technology
for complying with the US EPA’s NOx standards
since 2009 and the future European 2014 Euro6 NOx
standards.
12
Automotive Exteriors
Bumpers core business
Audi A6 bumpers
The front and rear bumpers made by Faurecia reflect
the perceived quality expected of Germany’s leading
automaker in the premium segment. Faurecia also
poured its ample expertise in the field: a painting process ensuring a faultless paint stretch, a management
of fit and finish in line with the premium requirements
of Audi, as well as a perfect integration on the front
with the large and low Singleframe grill, featuring bevelled upper corners.
advantages of Faurecia’s bumpers are perceived quality, better gap & flush, precise color and gloss matching, and resistance to minor bumps.
Citroën DS3 front bumper
In addition to its distinctive and versatile design, the
DS3 is packed with Faurecia expertise to protect pedestrians, including Faurecia’s patented metal-polypropylene hybrid front-end carrier, which provides excellent
absorption. As on the Citroën C3, the bumper incorporates a panel strengthener and “compliant” system
that ensures a tight fit and finish between parts. With
its sculpted style and distinctive looks, the DS3 is a real
head-turner, not least because of the LED-based Daytime Running Lights (DRL) tucked into the front end,
which create a dynamic feel suggesting a fresh driving
experience, and allow the vehicle to comply with the
new regulations, undeniably a design asset.
BMW M5 front bumper
Faurecia has developed and supplies complete front &
rear bumpers reflecting the high-level of fit and finish
for the M5 specific sports exterior parts. The design of
the front bumper clearly embodies the supreme power
of the new V8 engine. The wide-spread arrangement of
the customary M black slats – like the three air intakes
in the lower section of the front apron – emphasize the
cooling air requirement of the engine behind the grille.
The arrangement of the air intakes over various levels
Ford C-Max
The front and rear bumpers for the Ford C-Max and
Grand C-Max made by Faurecia in Spain, reflect the
Kinetic Design that Ford has successfully deployed
across its vehicle range. With its dynamic front and
rear-end styling, clean lines and superb trapezoid
grille, the Ford C-Max has a decisively contemporary
look. Faurecia’s one-piece front bumper is on of the
key elements of this look. The front-end has also been
designed to offer better protection for pedestrians,
with a reshaped fascia to help cushion the impact. Not
to be outdone, the rear bumper is fully at home in this
sporty environment.
creates an impressive depth which underlines the dynamic, forward-thrusting appearance of the Saloon.
The two side air intakes, meanwhile, have a dynamically curving form. Positioned far to the outer edges
of the car, they emphasize its wide track and fill the
spaces in the front apron, normally reserved for the foglamps in the BMW 5 Series Sedan. At the lower edge
of the front end, air-channeling flaps developed on the
race track ensure optimized aerodynamics. The main
13
Mercedes-Benz SLS AMG front bumper
Complete product range
The Mercedes-Benz SLS AMG front bumper engineered and developed by Faurecia, reflects the high-end
sports positioning of the vehicle. The bumper is painted using so-called “flat paint” a new painting process
which gives vehicles a new excusive and less shiny and
glossy aspect. Faurecia’s expertise in making bumpers
with complex geometry parts is applied to the SLS
bumpers using mat varnish. The advantages are a highly visual attraction, perfect fit-and-finish and unique
customization.
Front & rear bumpers: Audi A6
The color charts for the Mercedes-Benz SLS AMG
include nine exclusive paint finishes. The highlight
comes in the shape of the unique «AMG ALU-BEAM
silver» paintwork: the new, unique process makes the
paint shine like liquid metal. The paint covers the body
panels like a metallic skin, emphasizes the scintillating design lines of the ‘Gullwing’ more strongly than
any previous paint job and makes them even livelier by
means of targeted light reflections. This effect is made
possible thanks to tiny pigments measuring between
30 and 50 nanometers. The two matt finishes «designo
magno allanite grey» and «AMG magno sylvanite grey»
are just as eye-catching: with their matt silk surface
they reinforce the sporty character of the two-seater
through specific contouring of the crease lines.
Renault Kangoo Be Bop
The front bumper of the Renault Kangoo BeBop is a
specific two-tone version, where Faurecia is in charge
of the injection process, painting and final assembly.
Esthetically, this bumper features a two-one aspect: in
body color for the fascia and in platinum grey for the
central so-called “plastron” part, which bears the license plate. Faurecia has a proven track record in managing the complete manufacturing of a high diversity
of finished products for the same vehicle.
Faurecia is producing both the bumpers (front &
rear) and rocker panels of the Audi A7 from its plant
in Pappenheim, Germany. They meet the high perceived quality standards demanded by the German
premium segment leader. Faurecia also poured its
ample expertise in the field: a painting process ensuring a faultless paint stretch, a management of fit
and finish in line with the premium requirements of
Audi, as well as a perfect integration on the front with
the large and low Singleframe grill, featuring bevelled
upper corners.
Front-end module: Audi A6
Faurecia supplies a complete front-end to Audi
plants. Developed and patented by Faurecia, “mEasy”
is a mechanical system that eases the assembly of
this front-end on the vehicle directly on the OEM’s
assembly line. Perceived quality is ensured by the
“mEasy” arm which allows perfect fitting with the
car body. This arm is in itself unique. Indeed, a final
Z-shaped setting can be made at the last moment on
the assembly line to adjust the headlight and bumper
simultaneously to the hood. The module incorporates
an array of functions such as cooling, and shock
absorbers. The result: reinforced perceived quality,
management of diversity and vehicle weight reduction.
Supporting the front-end, the carrier displays a major
innovation. Indeed, it is made of hybrid aluminum and
polyamide. The goal of this carrier is to meet torsion
constraints of the vehicle, constraints with hood locks
as well as heat resistance. For the Audi A6, reaching
only 2.8 kg on a carrier has been a real challenge that
Faurecia’s product and process engineering has been
able to meet.
14
Liftgate: Ford Kuga
From grille to tailgate, Faurecia has invented new ways
to envision automotive exterior systems and modules,
reducing weight dramatically while simultaneously increasing convenience and safety for drivers, passengers and pedestrians. Faurecia has introduced clever
new automotive exterior products with a sharp new
focus on our principles of lighter weight, lower fuel
consumption and customization to gain adaptability
and design freedom.
Since the invention of the station wagon, the tailgate
has raised images of a heavy, bulky, difficult-to-operate
system. With its fully functional thermoplastic liftgate
for the Ford Kuga, however, Faurecia has elevated ease
of use and slashed the weight of the tailgate. Instead
of being fashioned conventionally from steel, this firstof-its-kind tailgate is molded from thermoplastic,
painted and equipped with foam inside the door for
sound deadening. This breakthrough product reduces
the weight of the liftgate by as much as 40 percent
(7 kilograms). It also enables manufacturers to save
as much as 70% on their tooling investment. Equally
important, designers gain new freedom in shaping
the liftgate to reflect the lines and individuality of each
vehicle model. The system is capable of integrating all
tailgate elements, including the rear window, spoiler,
structures and panels. The Faurecia thermoplastic
tailgate is currently in full production on the Ford Kuga
crossover utility vehicle in Europe.
Rocker panels: Mercedes-Benz SLS AMG
The Mercedes-Benz SLS AMG rocker panels (or side
skirts) engineered and developed by Faurecia, reflect
the high-end sports positioning of the vehicle. The side
skirts are painted using so-called “flat paint” a new
painting process which gives vehicles a new excusive
and less shiny and glossy aspect. Faurecia’s expertise
in making rocker panels with complex geometry parts
is applied to the SLS bumpers using mat varnish. The
advantages are a highly visual attraction, perfect fitand-finish and unique customization.
The color charts for the Mercedes-Benz SLS AMG
include nine exclusive paint finishes. The highlight
comes in the shape of the unique «AMG ALU-BEAM
silver» paintwork: the new, unique process makes the
paint shine like liquid metal. The paint covers the body
panels like a metallic skin, emphasizes the scintillating
design lines of the ‘Gullwing’ more strongly than any
previous paint job and makes them even livelier by
means of targeted light reflections. This effect is made
possible thanks to tiny pigments measuring between
30 and 50 nanometers. The two matt finishes «designo
magno allanite grey» and «AMG magno sylvanite grey»
are just as eye-catching: with their matt silk surface
they reinforce the sporty character of the two-seater
through specific contouring of the crease lines.
15
Notes
16
Notes
17
Notes
18
About Faurecia
For its first participation at the Frankfurt Motor Show since 1999, Faurecia – the world’s sixth largest automotive
equipment supplier – will present its technology leadership in its four Business Groups: Automotive Seating,
Emissions Control Technologies, Interior Systems and Automotive Exteriors. The Faurecia booth is located in
Hall 5.1, Stand # B12.
Contacts
Faurecia
Olivier Le Friec
Media Relations Manager
+33 (0)1 72 36 72 58
+33 (0)6 76 87 30 17
[email protected]
achtung! GmbH
Mark Jeznach
Consultant
Straßenbahnring 3
20251 Hamburg
Telefon: +49 40 45 02 10-1909
Telefax: +49 40 45 02 10-999
[email protected]
www.faurecia.com/pressroom
media.faurecia.com
ww.faurecia-newsroom.de
Crédits photos : Audi - BMW - Citroën - Daimler - Ford - GM - Renault - Volkswagen
19
Faurecia Group Communications 2011

1 Technology Highlights

Transcription

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