November 28, 2013: Benecke-Kaliko's Acella premium leatherette for automotive interiors can barely be distinguished from real leather. Thanks to its anti-aging and wear resistance properties, which are claimed to be significantly better than those of real leather, a range of automotive manufacturers use it for the seating areas of passenger cars. In addition to being used on upholstery, the material is typically also found on instrument panels, door inserts, gear stick and hand brake cowling, and soft-trim headliners.
The company says Acella is many times more cost efficient than leather, but its clear advantages extend far beyond the price tag. Compared to chemically treated leather, where it is difficult to maintain a consistent quality in terms of grain, colour, thickness, and density, Acella can be relied upon to combine uniform quality with the high-class look and feel of leather – a homogeneous surface design.
Exacting requirements
"Our materials are expected to satisfy even greater requirements than those of real leather," notes Sven Ullmann, Benecke-Kaliko's area management for Asia. These requirements include resistance to wear and abrasion, scratch, chemicals, and cleaning materials as well as resistance to aging despite exposure to UV light, heat, and moisture. It also exhibits low flammability. Acella's temperature resistance is significantly higher than that of real leather, which tends to become brittle due to its temperature sensitivity. It is not susceptible to excessive glossing during processing and does not grow brittle through use. It also exhibits high low-temperature flexibility, which is particularly important if the material is used in airbag systems. With the right combination of backing fabric and coating material, the production process can be tailored to achieve the desired mechanical, physical, and chemical properties.
Because similar additives are used to finish both real leather and Acella, it can also be easily processed in combination with real leather without any unintended interactions. This makes it possible to use Acella to create surfaces with an incredibly sophisticated, leather-like feel. The artificial leather can also be complemented with long-lasting anti-squeak additives, if required.
Another advantage is its processing flexibility. It can be back-moulded or stitched. Acella is easier to transport than leather and, unlike real leather, it can be cut with an automated laser cutter-like textiles without creating enormous quantities of scrap thus saving almost 20 percent on processing cost. And its high grain stability makes it possible to expose the decorative material to high temperatures or pressure during processing.
The company says Acella, which is used in all A, B and C class areas of seats including insert, bolster, side and rear of all rows in passenger cars, can provide up to 80 percent cost savings against real leather seats.
Photograph: Attractive, durable, and environmentally friendly: Acella cover material from Benecke-Kaliko.