Automotive seats are one of the key targets for vehicle lightweighting. As seats are significant components within a vehicle, reducing their weight has a substantial impact on the overall weight of the vehicle. Here are some real-world examples of lightweighting in automotive seats:
In 2021, General Motors (GM) applied a magnesium seat frame to their new full-size SUVs. Magnesium is a metal even lighter than aluminum, allowing for a significant reduction in weight compared to traditional steel frames. GM utilized die-casting techniques to create complex-shaped magnesium seat frames, reducing the seat weight by over 20% while ensuring strength and durability. These lightweight seats contribute to improved fuel efficiency and driving performance.
Ford has applied lightweighting technology to its Multi-Contour Seats, which feature various air cushions that adjust the seat shape to fit the driver's body. Ford used glass fiber-reinforced polyamide (PA) for these seats, an engineering plastic known for its excellent strength and durability, while being significantly lighter than steel. By optimizing the seat structure and strategically applying materials, Ford achieved both lightweighting and premium functionality.
Toyota has utilized foamed polyurethane to lighten their seats. Traditionally, seats used steel springs and thick foam pads, but Toyota replaced these with high-performance foamed polyurethane. This new foam material maintains elasticity and support while reducing density, significantly decreasing seat weight. Additionally, Toyota optimized foam thickness and improved ventilation structures to enhance comfort. The foamed polyurethane seats contribute to vehicle lightweighting and improved ride comfort.
Audi is researching the production of seat cushions using 3D printing technology. 3D-printed seat cushions can have complex internal structures, making them lighter than traditional foam pads. Audi applied optimized lattice structures to their 3D-printed seat cushions to minimize weight while ensuring sufficient support and comfort. Moreover, 3D printing enables the creation of custom seats tailored to individual passenger body shapes, providing a personalized seating experience.
Automakers are employing various lightweighting technologies in seats to reduce vehicle weight and enhance performance. Seat lightweighting efforts are not only focused on reducing weight but also on improving ride comfort and safety. We can expect to see continued innovation and new ideas in the pursuit of lightweight and premium automotive seats in the future.
Approaches include the introduction of lightweight materials, structural optimization, and the use of innovative technologies like 3D printing.
