Dual-Option Insert Carbon-Fiber Composite Fuel-Filler Door

This fuel-filler door design features inserts of either injection-molded and painted MPPE/PA6 (in black, metallic silver, or red to match body paint) or compression-molded and clear coated carbon fiber-reinforced composite with visible weave. The unique design of the system accommodates either the 2.0 mm-thick injection molded or the 1.0 mm-thick compression molded insert. The specially designed tool enables the Camaro name (with a 0.25  radius) on the fuel-filler door to be painted. Proprietary material is used for the visible-weave carbon composite version and a special clear coat on that insert offers 75% savings.

OEM/Vehicle General Motors Co. 2017 Chevrolet Camaro System Supplier Polytec FOHA Inc Material Processor    NOVO Plastics Inc

Material Supplier Mitsubishi Rayon Co., Ltd, / SABIC / Basler Resin Pyrofil Carbon Fiber / Noryl GTX PA6/PPE / Urethane Clearcoat Tooling/Equipment Supplier Integrity Tool & Mold Inc.

For More Information See: http://www.plastics-car.com/Partners/Trade-Associations 

PHEV Battery Pack

This next-generation battery pack features significant design improvements from its predecessor, including greater component integration, robust fuseable ICB board, and lightweight all-plastic structural elements, which eliminated a steel end plate and saved approximately 15% of the weight of the earlier system. As an added safety feature, the new design circuit contains fuses intended to interrupt the circuit in the event of a downstream short circuit.  The MPPE/PA resin's dimensional control and property retention in coolant helped achieve a durable thin-wall design.

OEM/Vehicle General Motors Co. 2016 Chevrolet Volt System Supplier General Motors Material Processor MH, ICB&ICB flex-board suppliers

Material Supplier SABIC Resin NORYL SE1GFN2 PPE/HIPS

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

Electric Vehicle Battery Pack

A dimensionally precise snap-fit design allowed for the development of a unique, simplified, lightweight cost-effective Li-ion cell packaging that supports automated assembly and contains no fasteners.  This led to improved battery module package density enabled via MPPE's low warpage, hydrolytic stability even in humid environments, and ability to be molded in thinner walls. The material also supports ultrasonic welding of the bus-bar face plate to the battery module.

OEM/Vehicle Ford Motor Co. 2012MY Ford Focus - Electric System Supplier Ford Motor Company Material Processor Toledo Molding & Die, Inc.

Material Supplier SABIC Resin Noryl GFN1 PPE

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

Ni-MH Battery Cell Enclosure

This is the first use of engine coolant as a cell-cooling medium for Ni-MH battery cells for a hybrid cross-over utility vehicle.  A special PPE/PE copolymer provides lightweight stiffness, creep resistance, and seals out moisture for this battery cell enclosure while providing resistance to alkali battery and coolant chemicals.  The high-productivity resin provided excellent molding productivity in thin walls.  A special film-insert molding process and secondary welding technology were also developed for this application. The unit saves an estimated 2.3 kg vs. alternative resins considered for the application.

OEM/Vehicle BMW 2010 ActiveHybrid X6 System Supplier Cobasys LLC Material Processor PM Plastics Co.

Material Supplier AsahiKasei Plastics Resin Xyron EV-103 PPE + PP Tooling/Equipment Supplier Arlen Tool Co. Ltd.

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Engine-Components

Ni-MH Battery Package for HEV

Injection molded modified-PPE resin was used for this compact Ni-MH battery module package, providing greater dimensional accuracy than glass-reinforced PBT and lower weight vs. glass-reinforced PPE/PS.  The resulting assembly is 50% lighter than it would have been in die-cast aluminum and 5-10% lighter vs. competitive GR-PBT or GR-PA, making it the best material choice for the required properties at low weight.

OEM/Vehicle Volkswagen AG 2010 Volkswagen Touareg Hybrid CUV System Supplier Sanyo Electric

Material Supplier SABIC Innovative Plastics Resin Noryl SE100P M-PPE

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