Crash-Boxes for Truck-Cabin Occupant Protection

Injection-molded PC/PBT was used to form left and right side crash boxes that allowed the commercial truck OEM to meet the very high (30kJ) impact energy of this crash requirement in India.  The versatile design allows both left- and right-hand parts to be  molded from the same tool while reducing weight 30% vs. the previous steel system.

OEM/Vehicle Volvo-Eicher Commercial Vehicle Pvt Ltd. 2011 India 7T LCV commercial truck System Supplier Machino Plastics Ltd. Material Processor Machino Plastics Ltd.

Material Supplier SABIC Innovative Plastics Resin Xenoy 1102 PC-PBT Tooling/Equipment Supplier Machino Plastics Ltd.

For more Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Safety

Advanced Material Characterization for Interior Parts

Use of advanced material characterization of plastics enables improved analytical modeling and therefore proveout of parts molded from these materials.  Advanced analysis tools are used to predict crack propagation, high strain-rate behavior, anisotropic properties of glass-filled plastics, creep data, and more for injection-molded thermoplastics, enabling engineers to design closer to the theoretical limits of materials and saving 10-20% weight for interior plastic components. This leads to a 5-15% reduction in material costs and a $500,000 USD reduction in testing costs per program.

OEM/Vehicle Ford Motor Co. 2012 Ford Explorer SUV

For More Information See: http://www.plastics-car.com/Processing

1-Piece Structural TPO Aero Rocker Molding

A patented, non-traditional injection molding process, where a chemical foaming agent is combined with TPO, was used to produce this rigid 1-piece structural component that met customer requirements while maintaining a Class A surface and lowering weight and part count vs. previous processes.  The innovation saved 2 parts and 3.86 lb / vehicle, resulting in a $7.6-MM USD direct cost savings and an additional $1.0-MM USD estimated indirect cost savings due to reduced part complexity and assembly-plant labor.

OEM/Vehicle Ford Motor Co. 2012 Ford Edge SUV System Supplier ABC Group Material Processor ABC Group

Material Supplier LyondellBasell Advanced Polyolefins USA, Inc. Resin Sequel TYC 852P TPO Tooling/Equipment Supplier Delta Tool

For More Information See: http://www.plastics-car.com/FAQs/Plastics-Processing.html 

Plastic Oil Strainer

Moving from traditional welded steel to plastic for the oil strainer saved 100 g of weight, a 50% reduction, for improved fuel economy. Vehicle testing (at over 200,000 km of driving) confirms the durability of the application. A 35% glass-reinforced polyamide 6/6 was used for strength and chemical resistance and was overmolded onto the steel-mesh screen for a stronger bond and increased durability.

OEM/Vehicle Hyundai Motor Co. 2011 Hyundai i10 subcompact System Supplier Sambo Motors Material Processor Taeyoung Chemical

Material Supplier Desco Resin GF PA Tooling/Equipment Supplier Dongshin Hydraulics

For more Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains

Mirror-Shell Bracket

By replacing glass-reinforced PBT and PET with this high strength and stiffness PP material, a 15% weight savings and $0.76 USD cost savings is achieved.  Excellent vibration-dampening characteristics were also important in the application. The material has since been expanded into folding mirrors where it also meets the durability requirements.

OEM/Vehicle General Motors Co. 2010 Chevrolet Equinox CUV System Supplier Magna International Inc. Material Processor Magna International Inc.

Material Supplier Asahi Kasei Plastics North America Inc. Resin Thermylene P7-60FG-0790 BK711 PP

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Body-Exterior/Auto-Trim.html

Anti-Stain Finish for Cloth Seats

Materials that typically soil and stain cloth are easily cleaned off even after significant wear takes place. Moisture-barrier, antistatic, and odor-resistant properties are also retained after wear.  The improved fluoroalkyl resin coating uses the same pad/spray application method as previous technology while reducing costs 15%.

OEM/Vehicle Hyundai-Kia Automotive Group 2011 Hyundai Soul CUV & Kia Optima mid-size sedan System Supplier Kolon Glotech Inc. Material Processor Kolon Glotech Inc.

Material Supplier Kolon Glotech Inc. Resin Cleantex Innoclean Polyester Tooling/Equipment Supplier Kolon Glotech Inc.

For More Information See: http://www.plastics-car.com/Upholstery?css=print

Low-Cost Automated Preform Fabrics

This new approach of using hook and loop fasteners on both sides of fiber plies leads to low-cost, 3D composites with increased strength and enable automation for layup of prepreg / preform fabrics. The new materials are able to make next-generation composites with a stronger interlaminate strength, impact resistance, compression strength, fatigue strength, bolt-hole strength, and bonding/connection strength for resin-transfer molding. The result is much faster ply layup due to easy handling of the plies. Use of advanced composites can reduce weight 40%, direct costs 50%, and indirect costs 30% vs. previous technology.

OEM/Vehicle Jiangsu Xinri E-Vehicle Co., Ltd. 2011 XR-EV05 electric delivery vehicle System Supplier Advanced Fiber Materials Technologies Co. Material Processor Advanced Fiber Materials Technologies Co.

Material Supplier Owens Corning Resin Araldite low-viscosity LY 564 Epoxy Tooling/Equipment Supplier Advanced Fiber Materials Technologies Co.

For More Information See: http://www.plastics-car.com/Upholstery

Bio-Polyurethane Foam in Automotive Seating Head Restraints

This head restraint foam uses 13 - 16% by weight (equivalent to 13-26% by volume) soybean oil-derived polyol to replace petroleum-based reactants in this MDI catalyzed polyurethane.  Ford’s use of bio-based foam in head restraints, seat cushions, and seat backs has helped the company reduce its petroleum usage by more than 3-MM lb annually and carbon dioxide emissions by over 15-MM lb.  The switch was cost neutral.

OEM/Vehicle Ford Motor Co. 2011 Ford Fusion & Lincoln MKZ Sedans System Supplier Lear Corp. Material Processor Lear Corp.

Material Supplier Lear Corp. Resin Bio-Based PUR Tooling/Equipment Supplier Lear Corp.

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior/Auto-Upholstery.html

Composite Underbody Shields

These ultra-lightweight underbody shields are used to improve aerodynamics for lower fuel consumption and to protect the vehicle’s undercarriage components from stone impacts.  The impact behavior is ductile so during a major impact the hole/damage will stay local and cracks will not propagate for better damage tolerance.  Low-pressure compression molding is used to form all parts in a single tool; waterjet cutting is used to cut them apart. There was  a 15-20% weight savings vs. injection-molded plastic.

OEM/Vehicle General Motors Co. 2012 Chevrolet Volt extended-range EV System Supplier Grupo Antolin-Irausa, S.A. Material Processor Grupo Antolin-Irausa, S.A.

Material Supplier Quadrant Plastic Composites Resin SymaLITE LWRT PP+GF

For More Information See: http://www.plastics-car.com/structure?css=print

B-Pillar Appliqué

This is a dual-shot (ABS over PMMA), injection-molded decorative pillar appliqué  provides excellent aesthetics  and electrical functionality for the vehicle’s keyless entry system.  It also provides glass guidance, replacing a steel u-channel.  Filling analysis was critical to the success of this design to prevent cracking and over-stressed parts in joints and corners.  The result is a 46% weight savings, a $1.4MM USD direct cost savings, and an additional $800,000 USD indirect cost savings.

OEM/Vehicle Ford Motor Co. 2011 Ford Focus compact car System Supplier Windsor Mold Group Material Processor Windsor Mold Group

Material Supplier Evonik Industries Resins Acrylite ABS, PMMA Tooling/Equipment Supplier Windsor Mold Group

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Chassis-Design-NVH-Performance/Support.html

Below Belt Glass Bracket

This multi-shot execution of a below-belt weatherstrip eliminates seal-unzipping failure mode.  It is an industry-first  use of a multi-shot/multi-function bracket that is overmolded to accommodate the glass-run sealing section without need for additional retention clips or u-channel welding/hemming.  As such, the PP/EPDM provides robust impact resistance and holding force even after heat aging and china dust exposure, reducing costs 60% vs. the previous method and providing the automaker a $900,000 USD direct and $400,000 USD indirect savings annually.

OEM/Vehicle Ford Motor Co. 2011 Ford Focus compact car System Supplier Brose Fahrzeugteile GmbH & Co. KG Material Processor Erwin Quarter, Inc.

Material Supplier RheTech, Inc. Resin PP T20T100 PP/EPDM Tooling/Equipment Supplier Camoplast Inc.

For More Information See: http://www.plastics-car.com/chassisdesign

Molded-in-Color Air-Register Bezel

The unpainted, low-gloss, PC/ABS Class A surface on these air-register bezels was achieved using injection molding / steam-mold technology and a new material with low gloss and UV resistance. The design also featured a unique method to interface with the chrome-plated ring. The innovation represents an indirect cost save of $1.80 per affected vehicle.

OEM/Vehicle Ford Motor Co. 2012 Ford Escape SUV / Kuga CUV System Supplier TRW Engineered Fasteners & Components Material Processor Fisher Tech

Material Supplier Samsung Chemical Resin  WP-1098 PC/ABS Tooling/Equipment Supplier Fisher Tech

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior/Other-Interior-Components.html

Low-Gloss, Molded- in-Color Steering- Column Cover

Use of a new lower gloss, molded-in-color ABS/PC blend eliminates the need for painted ABS/PC blends and provides improved thermal performance vs. straight ABS and PP. The part also provides improved dimensional stability vs. PP.  The application saves $1-3 USD / part depending on part size due to elimination of paint and associated scrap.

OEM/Vehicle BMW AG 2011 BMW 5 Series mid-size luxury sedan System Supplier Leopold Kostal GmbH & Co. KG Material Processor Leopold Kostal GmbH & Co. KG

Material Supplier SABIC Innovative Plastics Resin Cycolac DL100LG ABS/PC

For More Information See: http://www.plastics-car.com/steeringwheels?css=print