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  • Technical perfection, automotive passion

    Technical perfection, automotive passion

    Technical perfection, automotive passion

    Technical perfection, automotive passion

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    Press kitOctober 2-19, 2014Paris Motor Show Hall 1, Booth D521

  • Faurecia at the 2014 Paris Motor Show

    Faurecia presents its latest innovations in lightweighting and energy efficiency for cleaner vehicles and improved fuel economy.

    Faurecias technologies to develop cleaner and more fuel-efficient vehicles begins with weight savings. A 10 kg weight reduction of a vehicle lowers its fuel consumption and leads to a drop in CO2 emissions of 1 g/km.

    Through new product architectures and optimized design, the development and use of alternative materials and new production processes, Faurecia can offer weight reductions of up to 100 kg per vehicle within the 300kg package it provides. This reduction is achieved compared to traditional materials, and in particular through the use of composite materials.

    Weight savings are a vital part of innovation at Faurecia, leading to new design solutions and optimal

    steel thickness for seat structures and exhaust systems. To this end, composites pave the way for groundbreaking solutions to reduce the weight and ecological footprint of vehicles. Use of carbon-fiber composites can produce weight savings of 50% compared with steel. Faurecia has extensive expertise across the full range of composite partswhether painted or visible-carbon exterior parts, semi-structural or structuraland is present in all market segments, including mass-production models, sports & luxury vehicles and trucks. It continues to build on its leading position in weight-saving technologies, offering a solid array of processes to manufacture composite parts in high volumes for mainstream vehiclessuch as Sheet Molding Compound (SMC) and Resin Transfer Molding (RTM) technologieswhile demonstrating its expertise in optimizing multi-material structures and assembling parts that combine metal with composites.

  • In terms of fuel economy, Faurecia is also working on energy-recovery solutions. In an internal combustion engine, around one third of the energy contained in the fuel is dissipated in exhaust heat. Faurecia is developing technologies that can recover part of this available thermal energy to help reduce fuel consumption up to 3%. Once captured, the energy can be used to heat the cabin or accelerate engine-warming time. Faurecia is also working with automakers on new energy-recovery technologies to turn heat into electrical (or mechanical) power that can be immediately used by the vehicle.

    Faurecias 290 sqm booth at the 2014 Paris Motor Show (Hall 1, Stand D521) presents an array of products that illustrate the way in which it is helping to create cleaner, more fuel-efficient cars. Faurecia is especially involved in the project to develop an affordable vehicle able to travel 100 km on two liters of fuel, for which it has helped automakers to curb CO2 emissions by up to 7.5 g per kilometer. Some of these advances can be seen aboard some of the prototypes featured at the show, including the Peugeot 208 HYbrid Air 2L and the Renault EOLAB.

  • Contents

    Less is More demonstrator .............................................. 5

    Lightweight seat with optimized architecture ........................... 6

    Fiber glass composite vehicle floor ........................................... 7

    Composite carbon-fiber tailgate and lightweight bumper ........ 8

    Compact exhaust line ................................................................ 9

    Compact Exhaust Heat Recovery System (EHRS) ..................... 10

    Biosourced interior parts ........................................................... 11

    Lightweight window-lifter .......................................................... 12

    Hybrid crosscar beam ................................................................ 12

    Other products on display ...................................................... 13

    Magnesium seat structure ............................................................... 13

    Lightweight exhaust system ............................................................. 14

    SCR BlueBox compact mixer system ........................................... 15

    Complete seat system with Cover Carving technology .................... 16

    Complete lightweight seat mechanisms and

    structure of the Volkswagen up! ...................................................... 17

    Media contacts ............................................................................. 18

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    5Faurecia / 2014 Paris Motor Show

  • 1

    Less is More demonstrator

    Lightweight seat with optimized architecture

    Faurecia has successfully used innovative solutions to reduce the thickness and weight of the front seats, providing more room for rear passengers without compromising the safety or comfort of vehicle occupants. In the B segment, this has led to front seat structures that are 35% lighter than conventional counterparts in the same segment, largely through an optimal combination of different materials including steel, non-ferrous metals such as aluminum and magnesium, and carbon-fiber composites.

    Faurecia has also created a seat back that is 30% more compact by drawing on three areas of expertise:

    Optimized seat-back structure;A semi-stiff shell with an adaptive back mounted on the seat structure to tailor comfort to each individual shape of back;A smaller recliner.

    These technologies make it possible to reduce the weight of the rear shell by 40% while providing an extra 3 cm of leg room for passengers in the rear.

    All of these innovations allow automakers either to create a roomier vehicle with the extra 3 cm or to obtain an indirect weight saving of 3 kg if the length of the vehicle is reduced by 3 cm.

    Combined with the 4 kg shaved off the weight of each front seat through the use of innovative materials, this means Faurecia can offer automakers weight savings of up to 11 kg, or 1.1 g of CO2 per kilometer.

    This lightweight optimized seat has been chosen by Renault for its EOLAB prototype, presented on its booth at the Paris Motor Show.

    Faurecia R&D teams are now exploring which materials can best reduce the weight of seats while meeting industrial requirements..

    Less is More demonstrator seat

    6Faurecia / 2014 Paris Motor Show

    Renault EOLAB prototype seat

  • 2 To muffle the noise resulting from this drop in density, Faurecia has also improved the floor design by incorporating acoustic components into the empty space between the upper and lower layers of the thermoplastic structure.

    This approach to rethinking materials and design has put Faurecia in a position to offer a floor that is 16.5 kg lighter (11.5 kg in the front and 5 kg in the rear) than a conventional steel floor, reducing CO2 emissions by 1.65 g/km.

    The product achieves the goal of a 33% weight saving set by Renault for its EOLAB concept and could enter production four or five years from now.

    Fiber glass composite vehicle floor

    Faurecia engineers have developed an integral structural floor comprising a front and rear passenger floor and a trunk floor made of composite thermoplastic material reinforced with glass fiber, which is made using thermostamping techniques.

    In addition to offering outstanding mechanical performance to meet crash-test requirements and ensure recyclability, the polyamide-based composite thermoplastic (PA 6.6) with glass-fiber reinforcement also makes it possible to weld and over-mold parts. The technology reduces both weight and costs compared with bonding while producing a material able to withstand the very high temperatures created during cataphoresis.

    7Faurecia / 2014 Paris Motor Show

    Fiber glass composite vehicle floor

  • 3 Faurecias technology offers a number of other advantages in addition to the weight savings resulting from the use of composite materials, including:

    The removal of interior trim components as a result of the quality of the carbon-fiber material, which can be painted directly;The reduction in the number of parts to be assembled, such as the mechanisms (a single tailgate stabilizer);The integration of features to facilitate assembly (e.g. electrical-cable grooves);The ability to produce more complex shapes than with parts made of metal or glass, such as the rear window.

    The composite tailgate featured on the Peugeot 208 Hybrid Air 2L comprises a combination of plastic and carbon fiber, reducing weight by 35% or 7 kg. Thelow-cost carbon-fiber project (FORCE) launched by the Plateforme de la Filire Automobile (PFA) in France should make this material more affordable and ensure that it begins to appear on mass-production models in the next eight years.

    Faurecia has also trimmed the weight of bumpers by reducing their thickness from 3 mm to 2.5 mm, enabling weight savings in the region of 500 g for each bumper, or 1 kg per vehicle, representing an improvement of 11% compared with conventional bumpers.

    Composite carbon-fiber tailgate and lightweight bumpers

    Faurecias composite tailgate features a semi-structural design that consists of a skin and a lining with a thickness of