Fiberglass/Epoxy Composite Coil Spring

This weight-saving epoxy/fiberglass composite coil spring is the first of its kind to be used in the suspension system of a series-production vehicle. Using a patented, modified filament winding process, the application replaced traditional steel coil springs, reducing weight 40% and enabling the suspension system to react more quickly to changing road surface conditions, thereby improving vehicle handling and NVH. Significant work was done on resin chemistry and resin/fiber interface to ensure efficient load transfer and long-term mechanical performance,  as well as finding an efficient, cost-effective production method capable of meeting build volumes.

OEM/Vehicle Audi AG 2015 Audi A6 Avant 2.0-L TDI Ultra System Supplier S. Ara Composite S.A.S. Material Processor S. Ara Composite S.A.S.

Material Supplier Hexion Inc. Resin EPIKOTE Confidential Epoxy

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

Turbocharged Air Duct

This application combines the air-intake duct with charge air cooler and integrates both into the intake manifold, reducing air-intake loop volume by up to 50% (for better engine response) while also lowering package space 40% and part count, weight, and costs by 20%.  The resulting system reduces pressure losses so turbine work is reduced while keeping the same boost pressure at air-intake valves and helping reduce pumping work in the turbocharger 10% at high engine loads. Novel production technology (suction blow molding) and a new high-performance soft TPV (PA6 & ACM), which can withstand 2.7 bars of overpressure at 125C were used. There was no need for bellows, since the material was able to decouple engine movements from the intercooler by itself, and no internal protection layer was needed to protect the material from exposure to acidic blow-by fluids. Unlike conventional rubber, the part is fully recyclable at end of life. This led to a 50% direct and 50% indirect cost savings. Thanks to acoustic improvements, interior cabin noise also is reduced for occupants.

OEM/Vehicle Audi AG 2011 Audi A4 & A5 2.0L TDI & TFSI System Supplier Röchling Automotive Material Processor Röchling Automotive

Material Supplier ZEON Corp. Resin PA 6 + ACM Tooling/Equipment Supplier Röchling Automotive

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

De-Gas Bottle with Capacitive Plastic Sensor

By over-molding a 2-pin capacitive sensor of electro-conductive plastics directly onto the injection-molded de-gas bottle, a separate stainless-steel sensor assembly and its gasket are eliminated, which in turn avoids coolant leaks and corrosion issues of the previous system. This improves quality, reduces engine problems due to lack of cooling fluid, and lowers weight 2%, direct costs 15%, and indirect costs 15%.  A special device was developed to successfully overmold the electro-conductive pins.

OEM/Vehicle Audi AG 2008 Audi A6 executive car System Supplier Röchling Automotive Material Processor Röchling Automotive

Tooling/Equipment Supplier Röchling Automotive

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

Highly Integrated Spare-Wheel Well

This highly integrated, gas-assist, injection-molded spare-wheel well replaced steel and SMC with 60%-glass-reinforced PA 6 and an insert-molded aluminum inlay and screw inserts. Despite the high glass loading levels, the resin offers excellent flow and yields a part with very-good surface quality, while injection molding brought significant parts-integration opportunities. The final part is bonded into the body-in-white and therefore contributes to chassis stiffness, reducing weight 30% (vs. steel) and capital equipment investment by 70%.  It is particularly well-suited for small-to-midsize production runs owing to this tooling savings.

OEM/Vehicle Audi AG 2010 Audi A8 System Supplier Voestalpine Polynorm Group Material Processor Voestalpine Polynorm Group

Material Supplier Lanxess Resin Durethan BKV 60 PA6 GF 60% Tooling/Equipment Supplier Grupo Simoldes

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

Fully Structural Blow-Molded Seatbacks

These all-plastic, blow-molded PC/ABS seatbacks meet strict European safety legislation, including ECE 17 luggage retention, as well as other globally mandated requirements.  Because the PC/ABS blow-molded seatbacks replaced metal, a significant weight savings of almost 2.3 kg (5 lb) / vehicle was realized as well as a cost savings of $4 USD / vehicle.

OEM/Vehicle 2007 MY Audi AG Audi® TT System Supplier Lear Corporation Material Processor Moellertech GmbH

Material Supplier Dow Automotive Resin PULSE™ 2200 BG PC/ABS

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