20% weight loss! Toyota Tundra seat structure uses BASF’s polyurethane pultrusion material

Latest: Materials supplier BASF, design and engineering firm Flex-N-Gate, Toyota and pultrusion specialist L&L Products contribute to vehicle weight reduction for 2022 Toyota Tundra’s composite seat back design was awarded the prestigious Altair
Enlighten Awards. This is the second time in three years that BASF, L&L Products and Toyota have been recognized in the modular lightweighting category.

Vik, Engineering Chassis Group Manager, Toyota
Bhatia said: “Pultrusion technology has allowed us to design a seat structure that is 20% lighter than previous models and meet our cost targets. BASF, L&L Products and Flex-N-Gate are great partners, Helped us achieve our goals.”

The seat structure is the first interior application of L&L Products’ Continuous Composite Combination (CCS) technology using BASF’s polyurethane pultrusion combination Elastocoat
74850. CCS is a fiber-reinforced composite carrier with highly engineered sealants and adhesives in two-dimensional planes. The seat also features BASF’s impact-modified polyamide 6 Ultramid® B3ZG7
CR overmolded to create 60% of the 3D shape of the seat back.

Hank, Product Engineering Manager, L&L Products Division
“Through this partnership, we were able to reduce the assembly and scrap costs associated with metal seat structures by reducing the use of an all-steel assembly consisting of 60 stamped and welded parts and consolidating them into four composite parts,” said Richardson. It also makes the seat system more functional.”

“We continue to demonstrate the ability of pultrusion technology to provide lightweight, economical solutions with integrated functionality.” Kipp, Head of Thermoplastic Composites Technology, Performance Materials, BASF
“The unique design of the injection-molded pultruded beams in the seat structure also passes all relevant crash test requirements and opens the door to greater adoption of composite materials in automotive applications,” Grumm said.