L&L Products (United States)

Partner(s): BASF Corporation, United States - Toyota, United States

Taking an all-steel assembly that contained 60 stamped and welded parts and integrating it into 4 composite parts reducing weight by 20% while passing all relevant crash test requirements.

L&L Products CCS™ (Continuous Composite Systems) CCS™ are continuous fiber reinforced composite materials that can be used as a carrier when combined with our highly engineered sealants and/or structural adhesives. This two-dimensional part is designed to provide strength, stiffness, and rigidity to a lightweight structure. This is the first interior application to use L&L Products Continuous Composite Systems (CCS) technology with BASF’s polyurethane pultrusion system Elastocoat 74850.

CCS is a fiber-reinforced composite carrier with highly engineered sealants and adhesives in a two-dimensional profile. It was overmolded with BASF’s Ultramid® B3ZG7 CR, an impact modified polyamide 6, to create the 3D share of the 60% seatback. The seat structure is 20% lighter compared to the previous model. This is the first interior application to CCS™ technology taking an all-steel assembly that contained 60 stamped and welded parts and integrating it into 4 composite parts while passing all relevant crash test requirements.

L&L’s team of engineers bring extensive CAE modeling capabilities and are able to produce and optimize unusual part designs, therefore, obtaining part validation before parts are created.

Key benefits

• In-house engineering expertise
• Advanced CAE capabilities
• Ultra-high strength to weight ratio
• Competitive pricing
• Seamless integration of adhesives/sealants