Active Fuel-Management System

To boost fuel efficiency and reduce emissions on classic small-block pushrod V8 engines, an inexpensive and simple technology called active fuel management (displacement on demand) was developed. The efficient and precise electro-mechanical hydraulic system deactivates cylinder valves when power is not needed, then reactivates them when power is called for again. An important component of the system's solenoid control valves is injection molded, 30% GR-PEI, used for its high stiffness, creep resistance, thermal and chemical resistance, high knitline strength, and ability to be ultrasonically welded. The system improves fuel efficiency 5.5-7.5% and reduces cost 30% vs. metal.

OEM/Vehicle General Motors Co. 2012 5.3L V8 LH6 Engine System Supplier Eaton Corp. Plc. Material Processor    ITW Global Automotive

Material Supplier SABIC Resin ULTEM 2310 PEI

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

Transmission Range-Control Module Output Shaft Bearing

This injection molded PTFE-filled PEI resin bearing replaces powdered metal, which offered limited parts integration and drove the use of additional parts and retention processes.  The new design has 3 lobed locking features for bearing retention and integrated locating posts. The ID is the shaft bearing and the OD is the spring driver bearing. Despite design complexity, the part is molded without tooling action.  PEI's moldability, stiffness, and lubricity were key to its selection. The part reduces mass by 45% and cost by 50% vs. the previous metallic part.

OEM/Vehicle General Motors Co. 2016 Cadillac XT5,  Buick Lacrosse, and Chevrolet Bolt System Supplier Stoneridge, Inc. Material Processor    Stoneridge, Inc.

Material Supplier SABIC Resin ULTEM 4001 PEI

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

LED Headlamp Reflectors

High-temperature, lightweight PEI resin has replaced lacquered glass-reinforced BMC and PPS, or die-cast aluminum in this LED headlamp reflector.  High-polish SPI-1 finish on hardened steel tooling was required to get the reflector’s highly polished surface and the resin was formulated with a high-purity pigment package and low oligomers base resin.  The part saves approximately 50% weight and 30% direct cost vs. BMC, and an additional 10% indirect cost savings due to scrap reduction and recyclability.

OEM/Vehicle Hyundai Motor Co. 2010 Equus System Supplier SL Lighting Inc. Material Processor SL Lighting Inc.

Material Supplier SABIC Innovative Plastics Resin Ultem AUT200 PEI

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