International Conferences on Composite Materials

  4th Edition of International Conferences on Composite Materials

composite.sciencefather.com

Award Nomination - https://x-i.me/compram1

Abstract Submission - https://x-i.me/compabst2


Seat frame demonstrates next-generation autocomposites design


As more electric and hybrid electric vehicles launch into the market and hit the road, automotive OEMs are increasingly exploring composites use to reduce weight for various components to help increase vehicle range. One recent success is the award-winning, all-composite, second-row seat frame for the hybrid-electric 2022 Toyota Tundra pickup truck — a collaborative, multiyear endeavor introducing a number of new composite materials and process innovations.

John Salvia, senior engineering manager at Toyota Motor North America, Research and Development (Ann Arbor, Mich., U.S.), explains that in 2018, Toyota engineers at his Ann Arbor facility began to brainstorm “the next-generation truck.” “We started out looking at what would be the most efficient design moving forward,” he says, and specifically tried to envision how to make the design for vehicles with second- or third-row seating more efficient and cost-effective to manufacture. A range of materials were evaluated, including aluminum, carbon steel and various fiber-reinforced composites. 

The customer experience was also a key consideration. When it came to developing the 2022 Tundra, Salvia notes, customer feedback from the previous model year vehicle communicated a desire for more dedicated storage space within the cabin. However, this desire also had to be balanced with the fact that in the Tundra’s new hybrid option, the battery pack would be stored underneath the rear seat.

With the broad initial goals of cost-effective, efficient manufacturing, light weight and design flexibility to enable more storage space, fiber-reinforced composites emerged as the top material contender.

“Of course, we already had one proven composites example in our back pocket,” Salvia says. The third-row seat frame for the 2021 Toyota Sienna minivan was manufactured from injection molded 35% short glass fiber-filled polyamide 6 (PA6) developed in collaboration with BASF Corp. (Wyandotte, Mich., U.S.). The Sienna seat frame went on to win a 2020 Altair Enlighten Award in the Module category as well as a 2021 SPE Innovation Award in the Body Interior category. The Sienna seat frame was lauded for replacing the previous models’ 16-piece steel assembly with a two-piece composite part that was 30% lighter. BASF’s glass fiber-filled Ultramid B3ZG7 CR PA6 was developed specifically for the project (more on this below).

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