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The grill opening reinforcement is needed to absorb the energy during frontal impact, which is why the product design needs to be high in strength. Coats® Synergex™ technology uses our advanced commingling procedure, enabling us to offer an optimum fibre mix to reach the desired strength for this application.
In addition, the Lattice™ technology can provide the right fibre placement for the optimum design of the grill opening reinforcement.
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Since cars are usually heavier in the front due to the engine placement, it is important to get a solution that balances the weight with components that are being produced with lighter weight composites. The bonnet reinforcement uses our Lattice™ technology that can reduce the load without compromising the quality. Lattice™ is technology that allows us to place the fibre in a position and direction that is required by a specific application. No compromise by cutting fibres or in fibre placement is involved.
The versatility of using Coats® Synergex™ and Lattice™ is unprecedented. The innovative and durable fibre combinations allows a structural partition such as the bulkhead to have localised strength to the support system. The Lattice™ in particular uses continuous fibres that has high stiffness and strength qualities. However, each application is finely tuned to individual specifications to improve productivity and reduce costs.
Ability to use Lattice™ to intelligently position fibre in the load paths within the wheels provides the opportunity to increase performance whilst reducing waste and areas of overcompensation due to the use of fabric based solutions.
Coats® proprietary technology intimately commingles reinforcement fibres, like carbon and fibreglass, with thermoplastic yarns to produce a single mixed roving of uniform dispersion across its cross section.
At Coats®, we're keen to support sustainable development. Tests show that using carbon composites in car parts such as the wheel arch can reduce carbon dioxide emissions without affecting the car’s strength. Even the energy used to heat and up and cool down during manufacturing is reduced. See how the high performance automotive Rp1 benefitted from Synergex™
Synergex™ can be customised with a range of coatings and windings, as well as through different commingling and twisting processes.
We employ state-of-the-art core spinning technologies to produce knotless tyre cord weft yarn packages that minimises weft breaks, enables operation at high speeds, improves loom efficiency, reduces loom ‘shed’ and elongates uniformly under heat ageing dipped yarn conditions.
High elongation nylon/cotton core spun tyre cord weft yarns are principally used in radial tyres. For other applications, we also offer alternate unique substrates like Tencel® tyre cord weft yarns and fibreglass tabby yarns for piece end joining.
Our tyre cord weft yarns are approved by all major tyre manufacturers in the world.
Coats® Webflex™ HEN is manufactured by wrapping special air-jet or ring spun cotton fibre around a continuous filament nylon core, to form a yarn used in the weft of high performance tyre fabrics.
Coats® Webflex™ TEN is an air-jet core spun yarn manufactured using Tencel® which is stronger than cotton and used in the weft of high performance tyre fabrics.
Coats® Webflex™ COT is a cotton wrapped fibreglass yarn used to join rolls of tyre cord fabric.
Studies have shown that composites used in door impact panels can benefit the environment with its energy absorption capability reducing the temperature variations as well as reducing the weight of the panel by more than 50%. This is compared to Stamped Steel, and consolidation of parts allowing us to meet requirements with fewer composite parts than multiple pieces in stamped metal.
The preforms produced using our Lattice™ technology can be moulded into the desired shape by three different moulding processes such as resin transfer moulding, compression moulding or liquid composite moulding. Speak to us to find out which process would suit your needs.
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At Coats®, we are working in the automotive industry to help make significant strides and continuous efforts to remove additional weight from upcoming vehicles. Reducing vehicle mass is essential to meeting the fuel consumption and emissions targets. Our composite products can be integrated into multi-material automotive structures for maximum benefit to overcome the light weighting obstacle especially within the closure systems. Use of Synergex™ and Lattice™ in these applications show in excess of 60% weight reduction compared to the part in Stamped Steel, and consolidation of parts allowing us to meet requirements with fewer composite parts than multiple pieces in stamped metal.
The car seat lower design in Synergex™ and Lattice™ can afford in excess of 60% weight reduction compared to the same part in stamped steel. A variety of reinforcement fibres such as carbon, glass and aramid used in combination with the right matrix fibre such as nylon, polypropylene, PPEK and PPS can give you your optimum results.
Utilising Synergex™ allows the use of thermoforming or compression moulding which potentially reduces cycle time whilst increase re-cyclability. Lattice™ provides the ability to intelligently position fibre in the load paths within the seat back, which provides the opportunity to increase stiffness in areas of high stress and reducing material waste associated with fabric-based processes.
Special finishes are applied to our automotive threads used in stitching long, multi-layer upholstery fabrics and leathers. We also supply threads that are specially designed to tear in an accident and allow side impact airbags to deploy or seat belts to tighten.
Coats® Neophil™ is carefully engineered for the automotive industry and is best suited for safety critical applications. Our Neophil™ range of 3-ply bonded threads, is proven for its performance in the manufacturing of critical parts like seat belts and airbags. It is also ideal for sewing decorative stitches for gear stick covers and headliners. These threads were developed to survive high-speed, multi-directional sewing through multiple layers of fabric as well as withstand UV light for the lifetime of any car. Neophil™ is available in a full range of ready-wound bobbins to help enhance your productivity.
Coats® Dabond™ is a bonded, twisted continuous filament polyester thread that offers excellent protection against UV-light and abrasion. It is ideal for the interior of cars combining superior look with increased sewing productivity. Dabond™ is the only environmentally friendly bonded polyester thread available on the market and is excellent at resisting mildew, rot and the effects of bleaching. Its unique bonded and lubricated construction safeguards against ply untwisting in zip zag stitching, protects the needle from overheating and offers a smooth sewing experience even through several layers of heavy fabric.
Coats® Gral™ is a lubricated polyester thread made from pre-stabilised high tenacity continuous filament polyester. The soft finish with superior low friction lubrication helps you to reduce the effects of needle heat and abrasion. It’s an excellent sewing thread for all types of leather as its higher breaking strength and optimum stretch characteristics enables you to produce attractive, fine seams. Gral™ exhibits excellent loop formation, which gives you a consistent stitch formation and a neat seam appearance.
Coats® Aptan™ is a lubricated nylon thread made from pre-stabilised continuous filament nylon 6.6 and is suitable for garment dye programmes with nylon fabrics. It has a soft, low friction finish which reduces the effects of needle heat and offers excellent abrasion resistance. Treated with specially formulated lubricant, Aptan™ offers excellent frictional characteristics during high speed sewing operations. It has controlled stretch characteristics for good loop formation and tight, firm and balanced stitches. Aptan™ 6.6 nylon is 30% stronger than ordinary nylon 6.0 thread. The higher strength to fineness ratio makes possible the demanding fine seams found in automotive.
Discover more: Dabond™ Gral™ Aptan™
Neophil™
Car seat Embroidery is becoming an OEM/Consumer must have. Coats has a unique portfolio of products that will combine look with durability and productivity required in the interior of a car.
Coats® Sylko™ embroidery thread allows you to create beautiful, attractive logos and decorative seams on your car seats. It has excellent lustre and superior abrasion resistance for demanding end uses.
We offer a range of specialised high-strength sewing threads, specifically designed for critical automotive parts like seat belts. These threads can withstand challenging conditions like high abrasion and flexing over a long period of time.
The Opti™ S Zero Grin Reversed is a reversed zip with no space between the tapes. This ensures the spiral of the zip is completely concealed, making it invisible. Covering all the automotive standards for the interior, this zip is preferred due to the S-technology high lateral strength and flat surface, which gets incorporated in the back of the seat indistinguishably.
Zip interchangeability allows the zip to separate making a car sharing future easier to exchange and wash covers.
Opti™ spiral zips can be fitted anywhere in the fabric or leather and with the special sliding unit can bring add-ons like cushions and armrests to help the comfort of the driver or passengers.
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Opti™ spiral zips can be fitted anywhere in the fabric of the headrest. Usually, the zips remain inside and covered by the fabric allowing precise closing.
Using composite material such as Lattice™ can be beneficial in infotainment consoles for a number of reasons. Firstly, as with most applications of Lattice™, you're able to reduce the weight of the output sometimes by up to 50%. In addition, manufacturing an infotainment use a one shot process resulting in time and energy efficiencies. And to top it off, the sustainability benefits include reducing the amount of radiation emitted from the audio system.
Lattice™ is technology that allows us to place the fibre in a position and direction that is required by a specific application. No compromise by cutting fibres or in fibre placement is involved.
Coats® carbon fibre reinforced composites such as Lattice™ offer a high strength-to-weight ratio which is perfect for the supporting brackets. Not only can the structure withstand the load being applied, but it can also deliver significant energy savings.
Airbags are a safety critical product whose manufacturing demands a high quality sewing thread which can withstand demanding sewing conditions and not compromise seam integrity when sewing at high speeds through multiple layers of densely woven fabrics. While some automotive companies still use single-ply monochord threads for the airbag manufacturing process, a 3-ply twisted bonded thread is a better choice as it provides a more secure stitch.
Our sewing threads for steering wheel covers are built with a unique twist combination and are extremely resistant to the effects of abrasion and perspiration.
Coats® Brio™ is a lubricated polyester braid made from pre-stabilised, high tenacity, continuous filament polyester for machine sewing. Its low stretch characteristics, soft finish and superior lubrication offer exceptional sewing performance in high speed sewing machines allowing you to produce an attractive, controlled, fine decorative seam on leather steering wheels.
Coats® Gral™ is an excellent sewing thread for all types of leather as its higher breaking strength and optimum stretch characteristics enables you to produce attractive, fine seams. Gral™ exhibits excellent loop formation, which gives you a consistent stitch formation and a neat seam appearance.
The Opti™ S regular reversed zip is used to easily fit leather steering wheels by pulling the fabric close enough to be hand stitched efficiently. The zip is not visible and remains under the hand stitch.
Carbon Fibre Lattice™ Floor Impact Panels can be over 60% lighter than the part constructed out of stamped steel. The stamped steel part is also comprised of a larger number of components leading to higher tool and assembly costs.
Synergex™ and Lattice™ now allows Coats® to offer the industry cost effective means to reduce weight to significantly higher levels than what is being achieved by Aluminium, Magnesium and conventional Carbon Fibre and hybrid technologies. Coats® has jointly worked with equipment suppliers to speed up the process of the fibre laying step, Lattice™, to make the technology compatible with automotive needs.
Use of near net shape thermoplastic preforms provides the potential to reduce material waste whilst optimising component performance. The pressure applied on the pedals defines the strength of the material that is needed to give maximum security. Composites can be designed to be far stronger that aluminium or steel. Metals are equally strong in all directions, but composites can be engineered and designed to be strong in a specific direction.
Our sewing threads for automotive mats have extremely good sewing capability in severe conditions, as well as having abrasion resistance against footwear during use.
The Opti spiral™ zips sliding unit can be fitted in the floor carpet, allowing the seat to move forward and back whilst completely covering the seat rails for an aesthetically flat finish.
With the use of Synergex™ technology a tailored fibre mix can be used to reach the ideal strength and lightweight structure of a lift gate reinforcement. Furthermore the Lattice™ technology can help reduce the part count and the mass up to 30% and can increase production and cost efficiency. Complex liftgate surfaces can be formed much easier using composites compared to conventional metal parts.
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Using carbon fibre to produce exhaust brackets can further help to reduce the total weight of the car. Since research proves that reduced weight means better fuel efficiency, composite exhaust bracket parts made using our Synergex™ and Lattice™ technology will be optimal for your needs.
Synergex™ is technology that commingles dissimilar fibres and thereby tailoring the fibre mix to the performance and cost needs of a specific application.
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