Closed Loop Plastics & End-Of-Life Resin Use

Folding seat modules and plenum ducts are being produced with recovered 100% PCR PET resin from water bottles from CAMI Assembly Plant. The Lavergne Group Inc. has worked with GM CAMI Assembly Plant’s Global Environmental Compliance and Sustainability - Canada Region to implement the bottle collection program at the Lavergne facility. The recycled PET plastic is washed, flaked and turned into pelletized sustainable engineering resins. Bottle collection started in February 2017. This project is a demonstration of circular economy, bringing water bottles from CAMI, a landfill free, zero waste operation, processing them and returning those bottles in the form of a component to the same plant that generated the bottles.

OEM/Vehicle General Motors 2017 Chevrolet Equinox, GMC Terrain System Supplier Windsor Mold Group Material Processor    Windsor Mold Group

Material Supplier Lavergne Resin VYPET VNT 835 35% GFR, PCR, PET Tooling/Equipment Supplier Windsor Mold Group

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

Underbody Aero Shields

In this application, underbody shields using virgin glass/PP LWRT composites were replaced by a material made from PET fibers, half of which were sourced from recycled water bottles. The result was lower cabin noise/better acoustics, better thermal performance, a 2% cost savings, and a more environmentally responsible solution.

OEM/Vehicle Ford Motor Co. 2016 Ford Fusion System Supplier US Farathane Corp. Material Processor US Farathane Corp.

Material Supplier US Farathane Corp. Resin PET fibers Tooling/Equipment Supplier US Farathane Corp.

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

Seat Fabric from Recycled Materials

The fiber used in this innovative seat fabric is made from a hybrid blend of 100% recycled materials, including post-industrial fiber and post-consumer water bottles. The fabric meets Ford design and comfort requirements without any compromise in quality, durability, or performance. The switch from virgin fiber was achieved at cost parity, while providing significant environmental benefits, including diverting over 5-million water bottles from landfills just this year. To help close the loop further, there are now PET bottle collection bins installed at the Ford Research & Engineering campus, which are recycled to help form this fiber.

OEM/Vehicle Ford Motor Co. 2015 Ford F-150 System Supplier Johnson Controls Inc. Material Processor Sage Automotive Interiors

Material Supplier Unifi Manufacturing Inc. Resin REPREVE  PET

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

Fabric for Passenger Airbag Cushion

PET replaces PA fibers in the fabric of this passenger-airbag cushion (PAB) system.  This is the first time that PET has been used with hot-gas (pyrotechnic) inflators on PABs in North America.  The resulting polyester fabric met all validation requirements and performs just as well and as nylon fabrics but at 25% lower fabric costs.

OEM/Vehicle Ford Motor Co. 2014 Explorer SUV / Taurus sedan System Supplier Key Safety Systems Material Processor Key Safety Systems

Material Supplier GST AutoLeather Resin PET

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

PHEV Battery Covers

These EV battery covers help provide greater trunk-storage volumes despite the presence of large battery packs while protecting those batteries and providing easy access to the fuse box from the second row of the vehicle. Self-integrated attachment features are used where there is no room for conventional attachments, helping provide a clean appearance. Cold compression molding is used to shape carpet materials, while injection molding is used to form plastic components. By combining tooling for multiple carpet and plastic parts, cycle times, materials handling, and labor are reduced and significant tooling savings are achieved.

OEM/Vehicle Ford Motor Co. 2013 Fusion midsize sedan System Supplier Autoneum Holding AG Material Processor Janesville Acoustics

Material Supplier Washington Penn Plastic Co., Resin PP & PET Tooling/Equipment Supplier RCO

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

Decklid Trim with Self-Locking Feature

The initial design featured a straight slit on the decklid trim to allow a pass-through for installation over the trunk-lid hinges. However, this led to issues including visible sheet metal, poor retention, and poor appearance.  Use of hook & loop fasteners to join the trim worked, but added cost and labor, was challenging to install, and potentially contributed to squeak & rattle. Use of button or clip attachments also worked, but also added cost, labor, and tooling, plus was visible and had potential fit issues. The patent-pending solution was to cut a puzzle-shape feature via waterjet to make the trim cover self-locking. Now, appearance improved and operator assembly is easier, plus no costs were added and implementation time was short.  This led to 40-60 g weight savings, approx. $40,000-$50,000 USD primary and secondary tooling savings, plus a direct $1 USD/vehicle cost and $0.25 USD/vehicle labor savings while achieving good fit & finish and great appearance.

OEM/Vehicle Ford Motor Co. 2013 Fusion midsize sedan System Supplier Autoneum Material Processor Janesville Acoustics

Material Supplier Washington Penn Plastic Co., Resin PET Tooling/Equipment Supplier RCO

 For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior?css=print

Snap-in Slider on Side-Door Window-Regulator Hardware

This snap-in slider on the side-door window-regulator hardware is an industry first to provide friction for function and no squeak & rattle during window operation at low temperatures. The manufacturing process envelope was pushed to the maximum to satisfy the Taurus design theme of glass curvature

OEM/Vehicle 2010MY Ford Motor Co.: Ford®  Taurus® Sedan System Supplier Brose Material Processor Brose

Material Supplier BASF Resin C85A10  PET

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

Tufted PET Automotive Carpet

For the first time, tufted-PET carpeting has been used in an automobile. Containing 20 - 80% post-consumer-recycled content, and with the option to use 100% recycled PET, this tufted carpet meets or exceeds all major OEM carpet performance specifications, is 12-15% less expensive than traditional tufted nylon, and provides a sustainable solution.

OEM/Vehicle 2010MY GM Holden:  VE Commodore® Sedan System Supplier Futuris Automotive Interiors Material Processor Futuris Automotive Interiors

Resin Recycled PET

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

PET Side-Curtain Airbag

This is the first production application of PET fabric for side-curtain airbags in the North American market, replacing nylon 6,6 yarns.  The application makes use of unique PET yarns with spin finish and sizing.

OEM/Vehicle Ford Motor Co. 2010 Ford Escape System Supplier TRW Safety Systems Material Processor GST

Material Supplier Hailide Co. Ltd. Resin PET

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

Reinforced Airbag Lid in Foam (RALF)

RALF technology is an optimized instrument panel / passenger airbag door system that uses a reinforced structural 3D-skeleton of PET mesh textile  and polyurethane foam lid. RALF replaces the traditional metal or plastic airbag lid door and offers much improved airbag lid positioning with less risk of windshield breakage. It offers significant weight savings over traditional foam-in-place airbag construction and is cost-neutral.

OEM/Vehicle Ford Motor Co. 2011 Ford Focus compact car System Supplier Faurecia Interior Systems Material Processor Faurecia Interior Systems

Resins PET & PUR

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Safety?css=print

Flush Rear Center Sliding Window Assembly

The flush rear center sliding window assembly provides a pleasing aesthetic appearance for pickups due to a flush-mounted concealed window opening.  A patent-pending molded bulb seal provides a leak-resistant barrier and an excellent leak-proof water management system. This development can be applied to other OEM pickups.

OEM/Vehicle 2006 MY General Motors Full Size Pickups System Supplier Guardian Automotive Products Material Processor Guardian Automotive Products

Material Supplier DuPont Automotive Resin Rynite® 530 BK503 PET

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