Covestro, Votteler, Reichle, Merck: Car interior parts with seamless, intelligent surfaces

Covestro, together with a team of three industry partners comprising Votteler Lackfabrik GmbH & Co. KG, laser texture specialist Reichle Technology Center and Merck KGaA as a manufacturer of pearl effect pigments, has developed a cost-effective concept for the production of car interior parts with seamless, intelligent surfaces using its DirectCoating technology. The coated component is produced in two steps using a polyurethane reaction injection moulding (PU-RIM) process.

Car manufacturers and their suppliers face the challenge of integrating smart functions such as display and ambient lighting and touch control, in addition to a wide range of visual and haptic surface properties. Above all, the aim is to manufacture durable products as cost-effectively as possible in order to achieve broad acceptance in the industry. The goal is car interiors that can easily serve as a lounge, workspace and driver cockpit. In this way, an environment can be created in the car that combines comfort and infotainment with a feeling of safety.

Puriflow paint systems from Votteler enable outstanding surface properties such as good scratch resistance and a self-healing effect, but also a feel that ranges from soft leather to hard metal. These benefits, and the ability to create completely seamless surfaces, are thanks in part to polyurethane coating raw materials from Covestro.

In implementing the innovative solution, Votteler drew on the manufacturing expertise of Reichle Technologiezentrum GmbH, which operates Europe's largest laser texturing site. The company provided laser-textured PU-RIM moulds for the project. Covestro supplied process technology know-how, coating raw materials from the Desmodur and Desmophen ranges without solvent additives, and Makrolon and Bayblend polycarbonate plastics, which proved to be a key to the project's success. Effect pigments from Merck can be used to achieve various colour and transparency effects.

In Covestro’s DirectCoating process, the plastic substrate is first produced in an initial cavity by injection moulding. The resulting part is then transferred to a second, minimally larger mould. The cavity between the substrate and the laser-engraved RIM mould corresponds exactly to the desired volume of the coating that is injected there. This creates a coated precision part in just two steps. It requires little rework and is highly resistant to chemicals and daylight. DirectCoating also offers advantages over conventional coating methods, including a shorter and faster process, no overspray and no need for a separate drying step.

www.covestro.com
www.merckgroup.com
www.reichle.de
www.votteler.com

Covestro will showcase the project during Digital Expo 2021 from 14 – 16 September 2021. For more explanations, join Covestro experts Dr. Markus Mechtel, Thomas Michaelis and Esther Grau Zuriaga for a webinar starting at 10 a.m. CEST on 14 September 2021.