"Less is More" technology aims to lower fuel consumption, leading to a drop in CO2 emissions, by focusing on two key areas: weight savings and energy efficiency.
Through new product architectures and optimized design, plus the development and use of alternative materials and new production processes, Faurecia is set to offer weight reductions of up to 100 kg per vehicle, cutting CO2 emissions by 10 g/km.
Faurecia is developing energy-efficiency solutions to recover part of the thermal energy that is typically dissipated as exhaust heat, which can then be used to heat the cabin and accelerate engine-warming time. The Group is also working on new technologies to turn recovered heat into electrical or mechanical power that can be immediately used by the vehicle.
Click below to find out more about these innovations.
Our other innovations on the booth
A lighter rear
Faurecia has developed a composite tailgate that features a mix of plastic and carbon fiber, reducing weight by 35% (7 kg). This technology offers a number of advantages in addition to weight savings, including the removal of interior trim components, the reduction in the number of parts to be assembled, the integration of features to facilitate assembly, and the ability to produce more complex rear windows. Faurecia is also trimming the weight of bumpers through a reduction in thickness of 0.5 mm, enabling weight savings of 400 g per bumper.
Faurecia's Compact EHRS* can capture between 40% and 60% of the energy in fuel that is typically lost as dissipated heat in conventional exhaust systems, which is then used to warm the cabin and accelerate engine-warming time. The latest EHRS is more compact and is 50% lighter than the previous version, tipping the scales at just 2 kg.
*Exhaust Heat Recovery System
Complete seat system with Cover Carving technology
The Cover Carving technology developed by Faurecia engineers makes it possible to sculpt the back of the front seat to reduce weight and enhance perceived quality. The technology can be used to stitch the cover to the backrest frame itself, which reduces the overall thickness and weight of the seat while providing up to 3 cm of extra leg room in the rear.
Magnesium seat structure
The challenge for Faurecia lies in producing lighter seat structures that can nonetheless match the performance of today's systems through innovations that include using new materials such as composites or magnesium. Magnesium has a number of advantages: it is a very light metal with a low density and is easier to use than composites because of its homogeneous composition. A magnesium-alloy seat structure can, for instance, be 15% lighter than conventional steel structures, reducing the weight of the vehicle by nearly 4 kg.
SCR Bluebox® compact mixer technology
Faurecia's new SCR* Bluebox® compact mixer technology is designed to meet extremely stringent controls on nitrogen-oxide (NOx) emissions introduced by environmental standards now in effect and due to be tightened further in 2017. The system enables the use of a close-coupled SCR architecture, which ensures early SCR light-off to reduce NOx emissions sooner. Faurecia strongly believes that this close-coupled design will become the norm in the next few years. In addition to curbing NOx emissions, the compact system also significantly reduces the weight of the vehicle by between 3 kg and 4 kg, lowering CO2 emissions by 0.3-0.4 g/km.
* Selective Catalytic Reduction
Lightweight exhaust system
Peugeot called on Faurecia's expertise to develop a lighter exhaust system for its 208 HYbrid Air project, a prototype of a car able to travel 100 km on two liters of fuel. Faurecia reworked the exhaust design to shift the position of the rear muffler to the side. Other improvements included reducing the thickness of all stainless steel components used in the exhaust system to shave 0.4 mm off the thickness of muffler pipes and casings, and trim the baffles down to just 0.6 mm. The resulting exhaust system is nearly 2 kg (20%) lighter than the system used on the current Peugeot 208.