Nove trajnostne sedežne prevleke v Audiju A3

Reciklirane plastenke predstavljajo 89 odstotkov materiala sedežnih prevlek v novem Audiju A3. Zanimalo nas je, kako to pravzaprav deluje, zato smo obiskali tovarno tkanin, kjer nam je Ute Grönheim z oddelka za razvoj materialov povedala več o postopku, ki bi lahko Audiju omogočil okolju prijazno ravnanje z odpadki.

19.03.2020 Avtor: Audi Team  Fotografije: Arhiv Audi

Slika roke, ki ima v dlani Granulat, 100 odstotno izdelan iz recikliranih PET plastenk

Nakupovalne vrečke ali oblačila iz recikliranih plastenk najbrž že poznate, trajnostne materiale pa smo zdaj tudi pri Audiju postavili v središče razvoja. Na tem področju se skriva velik potencial: v enem avtu je okrog 340 kilogramov plastike, od tega je trenutno možno reciklirati približno polovico. V oddelku za razvoj materialov želijo to spremeniti. »Izdelati želimo trpežne sedežne prevleke, ki bodo prestale vse naše preizkuse kakovosti, hkrati pa bodo tudi trajnostne,« razlaga Ute Grönheim. Diplomirana tekstilna oblikovalka je zaposlena v oddelku za razvoj materialov, kjer so nastale sedežne prevleke novega Audija A3. Ena prevleka je narejena iz petinštiridesetih 1,5 litrskih plastenk iz polietilen tereftalata (PET). Ute nas popelje v zakulisje postopka.

“We only create things that can become real in some form. The technology has to exist to make the concept feasible.”

Christian Bolognesi, Italdesign spokesman

The Pop.Up Next concept doesn’t herald a flying car per se, but a self-driving, self-flying, fully autonomous, electric-powered taxi. It’s designed to operate on a multi-mode principle. Two passengers sit in a capsule, which, for driving purposes, is attached to a four-wheel ground module that is also electric-powered and fully autonomous. For flight mode, the capsule is autonomously detached from the ground module, then attached to an eight-rotor air module or drone capable of vertical take-off.

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Od plastenk do preje: sortiranje, mletje, topljenje

Podjetja za reciklažo uporabljajo le prozorne odpadne plastenke, saj jih je lažje barvati. Plastenkam najprej odstranijo pokrovčke in jih očistijo v posebnem pralnem stroju, nato pa jih z drobilnikom zmeljejo v majhne kosmiče. Tako nastane granulat, iz katerega izdelovalci preje naredijo poliestrska vlakna, ki bodo kasneje postali preja.

“Kakovost tkanine je enaka, končni uporabniki ne vidijo razlike.”

Markus Bartsch, vodja obrata

»Granulat je skoraj enak kot v drugih sedežnih prevlekah, le da je ta narejen iz recikliranega PET materiala,« pojasni Grönhein. Od industrijskega granulata se razlikuje tudi po tem, da zrnca niso tako enakomerno zdrobljena in čista. »Zaradi tega se lahko zamašijo šobe v postopku proizvodnje preje. Poleg tega je granulat iz recikliranih plastenk bolj moten, zaradi česar je manj vpojen in zahteva več barvila.« Izdelava recikliranih poliestrskih vlaken je zato nekoliko bolj zapletena in dražja.

V kolutih, ki tehtajo približno dva kilograma, prejo pripeljejo v tekstilno tovarno Willy Schmitz v nemškem Mönchengladbachu. Tu jo predelajo v blago za Audijeve sedežne prevleke. V proizvodni hali je 50 velikih tkalskih strojev. »Vzorec v tkalski stroj prenesemo z USB-ključem, nato vse poteka samodejno,« pove vodja oblikovanja Britta Gebhart. Stroji ropotajo, preja se vije prek valjev. Hrup v hali je oglušujoč. Dva stroja trenutno tketa blago 'Torsion', iz katerega bodo narejene sedežne prevleke novega Audija A3. 

Vodji obrata Markusu Bartschu je vseeno, ali je preja iz umetnega ali recikliranega materiala. Po postopku tkanja izdelek na videz in otip že deluje kot sedežna prevleka, a v resnici še zdaleč ni končan.

Tkanino najprej čakajo številni preizkusi kakovosti. Najpomembnejšega opravi Yvonne Peschmann, izkušena popravljalka tkanin, ki dobro ve, na kaj mora biti pozorna. Z izurjenim očesom opazi vsako odvečno nitko. Z rokami pretipa tkanino, da bi odkrila morebitne vozle ali zatrdline. Manjše napake s šivanko, sukancem in škarjicami popravi takoj, večje pa označi. Na ta način pregleda približno 200 metrov blaga v eni uri.

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Z blagom in flisom do sedežnih prevlek

Po pregledu kakovosti blago zvijejo in ga na posebnem pralnem stroju operejo pri 60 stopinjah Celzija. Pralni stroj ima več komor in lahko opere okrog 30 metrov blaga na minuto, v enem zvitku pa je okrog 600 metrov blaga – en pralni cikel torej traja približno eno uro. Po pranju blago zgladijo in posušijo.

Sedežne prevleke želimo v celoti izdelovati iz enega materiala – 100 odstotno recikliranega PET.

Ute Grönheim, Oddelek za razvoj materialov

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The journey is the reward

The company has already conducted a flight in public, at Drone Week in Amsterdam last year – but using a 1:4 scale model. The flight module accurately placed a passenger capsule on the ground module, which then drove from the test grounds autonomously. This proved the effectiveness of the Airbus coupling system and its locking and latching functionality. The air module currently rests on legs to make docking easier, but it’s envisaged that such legs would not be required by the time the concept reaches production.

To make the project with full-sized versions viable, more powerful batteries than those that exist today would be required, and Airbus is currently working on developing such technology. Noise is another issue, and reduction of the high-pitched whirring familiar to anyone who has witnessed even a small drone in flight is being sought. Italdesign is working with Audi to develop battery and electric-motor technology for the ground module – an area in which Audi’s engineers have already proven highly competent, as the recent launch of the e-tron SUV testifies. Therefor an Audi engineer is also based with the Italdesign team in Italy.

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The journey is the reward

The company has already conducted a flight in public, at Drone Week in Amsterdam last year – but using a 1:4 scale model. The flight module accurately placed a passenger capsule on the ground module, which then drove from the test grounds autonomously. This proved the effectiveness of the Airbus coupling system and its locking and latching functionality. The air module currently rests on legs to make docking easier, but it’s envisaged that such legs would not be required by the time the concept reaches production.

To make the project with full-sized versions viable, more powerful batteries than those that exist today would be required, and Airbus is currently working on developing such technology. Noise is another issue, and reduction of the high-pitched whirring familiar to anyone who has witnessed even a small drone in flight is being sought. Italdesign is working with Audi to develop battery and electric-motor technology for the ground module – an area in which Audi’s engineers have already proven highly competent, as the recent launch of the e-tron SUV testifies. Therefor an Audi engineer is also based with the Italdesign team in Italy.

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“Sedežne prevleke želimo v celoti izdelovati iz enega materiala – 100 odstotno recikliranega PET.”

Ute Grönheim, Oddelek za razvoj materialov

V naslednjem koraku je na vrsti pritrjevanje flisa na blago. S tem postopkom, ki se imenuje kaširanje, poskrbimo, da so avtomobilski sedeži udobni. »Trenutno uporabljamo plamensko kaširanje, pri katerem s plamenom stopimo tanko plast pene, ki jo nato skupaj s flisom prilepimo na blago,« razloži Gebhardt. Ko prištejemo še flis, reciklirane plastenke predstavljajo 89 odstotkov materiala za sedežne prevleke. »Naš cilj za prihodnost je, da bi uporabljali tako flis kot lepilo iz recikliranih materialov,« pravi Gebhardt.

Po končnem pregledu kakovosti in stresnem testu je delo v tovarni tkanin Schmitz končano. Blago za sedežne prevleke novega A3 odpotuje v naslednjo tovarno. V šivalnem studiu dobi svojo končno obliko, v tapetniški delavnici pa z njim preoblečejo sedeže. In je tu: končna trajnostna prevleka iz recikliranih PET plastenk za sedeže novega Audija A3.

 

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The journey is the reward

The company has already conducted a flight in public, at Drone Week in Amsterdam last year – but using a 1:4 scale model. The flight module accurately placed a passenger capsule on the ground module, which then drove from the test grounds autonomously. This proved the effectiveness of the Airbus coupling system and its locking and latching functionality. The air module currently rests on legs to make docking easier, but it’s envisaged that such legs would not be required by the time the concept reaches production.

To make the project with full-sized versions viable, more powerful batteries than those that exist today would be required, and Airbus is currently working on developing such technology. Noise is another issue, and reduction of the high-pitched whirring familiar to anyone who has witnessed even a small drone in flight is being sought. Italdesign is working with Audi to develop battery and electric-motor technology for the ground module – an area in which Audi’s engineers have already proven highly competent, as the recent launch of the e-tron SUV testifies. Therefor an Audi engineer is also based with the Italdesign team in Italy.

1920x2500-mobil-e-mobility-blue-sky-thinking-036

The journey is the reward

The company has already conducted a flight in public, at Drone Week in Amsterdam last year – but using a 1:4 scale model. The flight module accurately placed a passenger capsule on the ground module, which then drove from the test grounds autonomously. This proved the effectiveness of the Airbus coupling system and its locking and latching functionality. The air module currently rests on legs to make docking easier, but it’s envisaged that such legs would not be required by the time the concept reaches production.

To make the project with full-sized versions viable, more powerful batteries than those that exist today would be required, and Airbus is currently working on developing such technology. Noise is another issue, and reduction of the high-pitched whirring familiar to anyone who has witnessed even a small drone in flight is being sought. Italdesign is working with Audi to develop battery and electric-motor technology for the ground module – an area in which Audi’s engineers have already proven highly competent, as the recent launch of the e-tron SUV testifies. Therefor an Audi engineer is also based with the Italdesign team in Italy.

1920x2500-mobil-e-mobility-blue-sky-thinking-036

The journey is the reward

The company has already conducted a flight in public, at Drone Week in Amsterdam last year – but using a 1:4 scale model. The flight module accurately placed a passenger capsule on the ground module, which then drove from the test grounds autonomously. This proved the effectiveness of the Airbus coupling system and its locking and latching functionality. The air module currently rests on legs to make docking easier, but it’s envisaged that such legs would not be required by the time the concept reaches production.

To make the project with full-sized versions viable, more powerful batteries than those that exist today would be required, and Airbus is currently working on developing such technology. Noise is another issue, and reduction of the high-pitched whirring familiar to anyone who has witnessed even a small drone in flight is being sought. Italdesign is working with Audi to develop battery and electric-motor technology for the ground module – an area in which Audi’s engineers have already proven highly competent, as the recent launch of the e-tron SUV testifies. Therefor an Audi engineer is also based with the Italdesign team in Italy.

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AudiLab Slovenija

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