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Energy saving and the reduction of CO2 emissions represent two mega-trends which are contributing in driving the automotive market. The introduction of lightweight components is one of the actions which are taken to reduce the total weight of a vehicle, thus saving energy and cutting on CO2 emissions.

Load-floors, parcel shelves and sun roofs covers are semi-structural parts which can be manufactured using a lightweight composite sandwich made of three layers: a honeycomb cardboard core between two fiberglass mats. These materials are glued together by spraying polyurethane on both sides of the sandwich and compressing it in a dedicated mould.

Looking at the part itself, it is of utmost importance to spray a homogeneous and controlled polyurethane layer on both sides of the sandwich: this has to contain the minimum amount of PU necessary to keep the layers together and grant the part the necessary mechanical properties. Not only an excess of PU represents additional weight, but it is also a waste of money since more chemicals than necessary are consumed.

From the standpoint of the process, it is fundamental to tailor the plant according to the requested productivity, keeping an eye on the overall consumptions, layout and ergonomics. Cannon can provide turn-key solutions for diverse productivity levels –from relatively low volumes to extremely high volumes- with various level of automatization.