Lightweight Interiors Could Bolster Fuel Economy
Byron Pope Ward's AutoWorld, Jun 1, 2009 12:00 PM

Auto Makers and Suppliers Long have endeavored to shave weight from all areas of a vehicle, including the interior.

That goal becomes even more important following President Obama's mandate calling for fleet fuel economy of 35.5 mpg (6.6 L/100 km) by 2016.

Jeff Corkins, chief engineer-research and development for Magna International Inc.'s seating division, says his company has been working on lightening components for several years.

“In 2006, we saw 6% of SUV owners downsize,” he says. “Last year it was 21%. We see that trend continuing, but (consumers) still need to fit the same amount of stuff and people (in their vehicles). It's a challenge.”

One way to free up space is to reduce seat mass. In today's vehicles, the inner mechanisms and frame account for two-third of seat mass, Corkins says.

But formerly “exotic” materials, such as high-strength and ultra-high-strength steel, are finding their way into seating applications, without sacrificing strength.

Other materials, such as extruded aluminum, reduce seat mass but are not ideal because “steel components still need to be added,” Corkins says.

Magna has had success with diecast magnesium, which it used for the Chrysler LLC minivan seats. But that material suffers from low ductility, porosity and volatile pricing and requires secondary machining.

Molded magnesium may prove more promising. In a semi-solid state, the lightweight material can be formed using a process similar to plastic injection-molding, Corkins says, noting the material produces a high-quality surface and boasts excellent dimensional precision.

Creating environmentally friendly components also is important to Magna subsidiary Decoma International, says William Harney, executive director-research and development. He says the supplier is eying increased use of natural fibers and woods.

Faurecia North America employs a weight-reduction strategy dubbed “Light Attitude Innovation,” says Rob Huber, vice president-marketing and design.

Innovations from Faurecia have the potential to shave some 66 lbs. (30 kg) from a vehicle, he says. If the weight-savings were applied to a large-volume model, some 11 million barrels of oil would be saved over the platform's life.

To demonstrate its technologies, Faurecia created the Light Attitude Concept, which features a self-supporting instrument panel and the generous use of natural fibers.

In place of a traditional center stack, the concept boasts a “smart dock” that integrates devices such as an iPhone into the vehicle's display panel. “It uses the iPhone to eliminate the radio and can download (new) features,” he says.

The concept has thin seats with exposed structures for a futuristic look. With the demand for greater fuel economy and consumer migration toward smaller vehicles, it's “never been a better time to talk about reinventing the interior,” Huber says.