Airbag Support

This is the first known application where EPP foam replaces stamped steel for a passenger knee airbag support bracket. The 15 lb/ft3/240 kg/m3 density foam sustains airbag deployment reaction loads at all environmental conditions and reduces mass 88% and piece cost 55% vs. the incumbent design. The weight reduction led to other benefits, including elimination of 2 assembly-aid clips, ergonomic improvements, improved vehicle fuel economy, and reduced shipping costs. The simplified manufacturing process involves no secondary processes, eliminated 3 torque monitoring joints for additional manufacturing savings, and is backward compatible for serviceability.

OEM/Vehicle Ford Motor Co. 2017 Ford Explorer System Supplier ZF TRW Material Processor    The Woodbridge Group

Material Supplier JSP Resin ARPRO EPP Tooling/Equipment Supplier The Woodbridge Group

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

Cargo-Management Loadfloor System

The new utility cargo system, consisting of a 3-piece EPP foam support plus a twin-sheet TPO load floor, provides packaging of police/fire/emergency electronics and wiring, is lightweight and easy to install yet durable and functional, and allows for easy customization.  Recent structural modification of the vehicles to meet stringent police requirements meant the existing load-floor system could no longer be used.  The new system fits fine without interference to the body and can handle up to 800 lb/363 kg of loading.

OEM/Vehicle Ford Motor Co. 2012MY Police Interceptor Utility System Supplier Troy Design Material Processor Sonoco Protective Solutions Century Plastics

Material Supplier JSP / Spartech Corp. / Northwood Resin EPP / PP / TPO

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

Dual-Purpose Cargo Management System

This patent-pending, dual-purpose, combination cargo-management system / load floor for a BEV helps organize / store occupant goods while providing an adjustable load floor (with single-hand operation) and access to the battery charge door underneath without having to remove the unit from the vehicle.

OEM/Vehicle Ford Motor Co. 2012MY Focus BEV System Supplier The Woodbridge Group Material Processor The Woodbridge Group

Material Supplier JSP BASF Corp. Resin EPP / PP

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

EPP Head Restraint Core for FMVSS-202a

This patent-pending safety application is the first time an expanded-polypropylene (EPP) foam head-restraint insert has been used to meet FMVSS-202a static requirements in a headrest.  Local depressions in the core are used to reduce permanent set during FMVSS-202 “backset” and “height” retention testing.  A unique snap-fit design is formed without the need for slides or lifters in the low-cost steam-chest tooling, providing a secure fit to the head-restraint rod and ease of assembly.  The core’s unique geometry allows for a large number of cavities (32) to be used in the mold, helping increase productivity and reduce piece costs. The application provides significant piece-price and tooling avoidance savings vs. injection- or blow-molded plastic cores.

OEM/Vehicle 2008 & 2009MY Ford Motor Co. Various Vehicles System Supplier Windsor Machine Group Material Processor Tegrant Corp.

Material Supplier JSP Resin Arpro® EPP Tooling/Equipment Supplier Tegrant Corp.

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

4-Way Adjustable EPP Headrest

A unique 2-piece EPP foam design allows for more comfortable, 4-way adjustable headrests that still comply with new safety requirements for rear impact conditions. Snapping into a metal assembly, a common rear EPP part mates with program-specific EPP front part to aid in bonding / assembly with minimal new tooling investment while also lowering weight.

OEM/Vehicle Ford Motor Co. 2011 Ford Explorer System Supplier Windsor Machine Group Material Processor Tegrant Corp.

Material Supplier JSP Resin Arpro EPP Tooling/Equipment Supplier Tegrant Corp.

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