Innovative table systems designed specifically for autonomous vehicles highlight the possibilities that thermoplastic composites open up in providing lightweight, rugged and high aesthetic value parts for future mobility.

Autonomous driving and car sharing will turn the interior of the car into a living and working space. As drivers become passengers, they will need a flexible interior compartment to adapt to new activities, such as working while on the go. A three-way consortium of Covestro, Austrian Engel and Dr. Schneider has developed a thermoplastic composite solution for lightweight but mechanically robust, foldable tables to meet such needs during autonomous driving.

Thin but sturdy

The table is 41 cm long and 32 cm wide, varying according to the style of the ultrabook, from 5 mm on the outside to 10 mm on the inside. It is designed so that it can be tucked away between the rear seats to save space.

This table is a sandwich construction. Its top and bottom are made of 1mm thick Maezio® Made of a polycarbonate composite reinforced with continuous carbon fibre. The sandwich core is a hard, low-density polyurethane foam based on Baydur 20. Both materials are from Covestro. Weighing about 690 grams and just under a centimeter thick, the table is very light and light, but very strong. It can carry 50kg, while the maximum load for a normal injection molded table of this size is 5kg.

Fully automatic composite molding

To make the table, the composite blank is placed in a horizontal infrared oven and heated to a molding temperature higher than the glass transition temperature. After heating, the soft semi-finished product is transported by an Engel Easix articulated arm manipulator to the duo 350 injection molding machine and transferred to an open injection mold. With the injection molding machine closed, the composite material is cooled after forming.

project work closely

project partners have different tasks in the project. Covestro designed the components, checked the adhesion properties of PUR foam, carried out CAE simulations of the load conditions, and determined the load direction of the fiber fabric layer. In addition, the overhang of the composite blade in the cutter was simulated to optimize production.

Engel's core tasks are heating materials, handling soft composites, and molding in an injection molding machine. Dr. Schneider has developed a tool with variable temperature control for composite molding, which ensures that the surface quality of the parts is flawless. In addition, the tool is designed in such a way that the inserts are placed evenly on the tool wall without forming wrinkles.

Florian Dorin, automotive composites specialist at Covestro, said: "Maezio® Thermoplastic composites have great potential for high stress and decorative lightweight components inside and outside of vehicles. But to achieve this, we need a very strong partnership, and that is what we have built with these two partners to enable the industry to adapt to the mobility trends of the future."