Thermoplastic Polyolefin Skin Instrument Panel

The use of TPO skin was recognized in the industry in 1999, when GM won the SPE® Most Innovative Use of Plastics Award in the Body Interior category. It improved safety by enabling air bag deployments, and reduced windshield fogging with the reduction of VOCs and odors without plasticizers and toxic stabilizers. The environmentally friendly all polyolefin system also enabled closed loop recycling and the replacement of PVC while reducing mass 10%. The TPO skin also improved interior quality by preventing brittle cracking, color fading (UV protection is improved by 4 times) and warping. Overall esthetics were improved by the dry haptic leather-like feel inherent in TPO skin.

OEM/Vehicle General Motors 2000 Pontiac Bonneville System Supplier Inteva Products LLC (Delphi Interior Systems) Material Processor    Inteva Products LLC (Delphi Interior Systems)

Material Supplier Mytex Polymers Resin TPO

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Current-Projects/End-of-Life-Vehicle-Recycling.html?css=print

Torsional Welding of PDC Sensors to Thin Wall Fascia

This is the first application of torsional welding (spin & ultrasonic welding combined) on automotive fascias. It allows welding of PDC brackets without localized thickening of wall stock on 2.5 mm, thin wall, molded fascias. An adjustable TPO material with high melt flow, high stiffness/ impact allowed for less material to be used resulting in a 10% reduction in mass for a 7% weight savings with $122,000 direct cost savings in three years. Cycle times were improved and there was no weld read through resulting in a quality appearance. Future applications or this process include fascia support brackets, fog brackets and more.

OEM/Vehicle Volkswagon AG 2018 Skoda Octavia System Supplier Magna Exteriors Material Processor    Magna Bohemia Liberec

Material Supplier SABIC Resin Sabic 8650 TPO Tooling/Equipment Supplier Changzhou Huawei Mold Co., Ltd.

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

Winged Spring Clip with 4 Way Locator

Metal clips and springs were eliminated by designing an in-molded W shaped plastic clip with a 4-way locator providing efficient attachment per requirements and eliminating additional costs for fasteners and assembly. The plastic part comes out of the tool with the clips molded in. The patented winged spring clip design locates, locks and retains in a single snapping action. A cost save of $0.17 per clip/$2.19 per vehicle resulting in $250K per year; and a 10% weight saving is achieved.

OEM/Vehicle Ford Motor Company 2018 Expedition/Navigator System Supplier Magna Seating Material Processor    Royal Technologies

Material Supplier Advanced Composites Resin ADX 5017 TPO Tooling/Equipment Supplier Tri Tech Tooling, Inc.

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

Non-weakened Skin for Seamless Airbag System

This scoreless skin technology eliminates the visible line of the airbag door. A special bi-laminate foil with TPO chemistry for unique tensile, shear and processing characteristics enables an improved surface appearance over previous scored IP skin constructions. Parts are injection molded with inmold lamination. No high capital expenses ($750,000 cost avoidance) for laser score equipment make this doable globally in low cost, low tech countries. The previous process included injection molding the substrate, cutting and sewing and hand wrapping the top skin cover and laser scoring the composite panel. Streamlining the production results in a $1.5/part cost saving. Since the skin is not weakened by scoring, the underlying substrate can be made weaker to enhance the airbag deployment door opening time.

OEM/Vehicle Ford Motor Company 2018 Ford EcoSport System Supplier Faurecia Interior Systems Material Processor    Faurecia Interior Systems

Material Supplier Haartz Resin Deploy Bilaminate TPO Tooling/Equipment Supplier GS Engineering

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

Ultra Capacitor Barrier Shield

This application uses material recycled from tires and plastic caps to make TPE shields to protect the ultra capacitor from the hotter surrounding environment by deflecting heat away from it. This has prevented 5,000 tires and 25,000 lbs of plastics from landfills to date. Die cutting, thermoforming and vibration welding is used to produce this part for the first time, opposed to 2-shot injection molding, resulting in an $80,000 savings in tooling compared to tooling for steel or aluminum used previously. A 16 week same save is also achieved. Consumers benefit as the heat shields keep the battery cool preventing possible battery failure. This application can be translated to other exterior applications.

OEM/Vehicle General Motors 2018 Cadillac CTS System Supplier GDC Incorporated Material Processor    GDC Incorporated

Resin Enduraprene 2390/2195Re TPO Tooling/Equipment Supplier GDC Incorporated

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

Integrated Floor Bedliner Divider

This first time twin sheet thermoformed bedliner divider is integrated into the bedliner as one piece. A $275 cost avoidance resulted by not having to manufacture a separate floor divider part. The divider incorporates a molded in locking feature to secure the divider into the truck wall when it is raised. It eliminates the need for a cargo net or separate divider allowing the customer to put smaller items in the bed without having the items move and slide around while the vehicle is in motion. Dual textures are achieved on both sides of the part and the design can be applied to different vehicle models and brands via an insert for different logos.

OEM/Vehicle General Motors 2017 Chevrolet Silverado System Supplier Penda Corp. Material Processor    Penda/Durakon

Material Supplier A. Schulman Resin Polytrope TPP1026EU TPO Tooling/Equipment Supplier Penda Corp.

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

High Desert Tonneau Cover

Achieving a grain in a thermoformed part that matches the same grain produced by injection molding resulted in an improved appearance with the tonneau cover harmonizing with other thermoformed and injection molded parts on the vehicle. It also enabled a $300/truck savings by enabling an aluminum honeycomb (in the previous vehicle design) to be replaced with a steel bar design. A new scratch resistant thermoformable TPO helped to make this possible.

OEM/Vehicle General Motors 2017 Chevrolet Silverado System Supplier Penda Corp. Material Processor    Penda/Durakon

Material Supplier A. Schulman Resin Polytrope TPP1026EU TPO Tooling/Equipment Supplier Penda Corp.

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

Modular Composite Front-Seat Cushion Pan

This patent-pending, plastics-intensive, modular composite front seat-cushion pan (in impact-modified 35% GR-PA), side-airbag deployment back panel (in talc-filled TPO), and power head-restraint drive nut (in POM) create a robust and dynamic crash-energy management system for front impact protection, side airbag deployment, and energy management for occupant impact protection. Further, the system enables modular assembly and scalable features for assembly ease.  Already 83 patents have been filed and 12 granted on this innovative seat system. 

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Leggett & Platt / Great Lakes Trim / Grammer Industries Material Processor    MacLean-Fogg / Grand Traverse Plastics / Johnson Electric

Material Supplier BASF Corp. / Advanced Composites, Inc. / DuPont Automotive Resin Many Tooling/Equipment Supplier MacLean-Fogg / Grand Traverse Plastics / Johnson Electric

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

Crash Box Integrated Rear Bumper Beam

This crash box-integrated plastic rear bumper back beam meets Korean regulations and RCAR requirements at 21% lower weight and 39% lower cost than the conventional steel rear beam it replaced. The center of the hybrid beam is compression molded from continuous-fiber-reinforced PP/glass composite to induce effective front impact energy absorption. The entire back-beam shape and crash boxes on either end are injection overmolded using 60% GR-TPO, which has been modified for low-temperature performance.

OEM/Vehicle Hyundai Motor Group 2016 Ioniq System Supplier LG Hausys Material Processor    Najung ENG

Material Supplier LG Hausys(CFT)/ LG CHEM(TPO) Resin LG CHEM 0 TPO Tooling/Equipment Supplier Najung ENG

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

Robotic Laser Cutting & Welding of TPO Fascia

A hydraulic punch and sonic welding operation was replaced by robotic laser cutting and welding of a Class A exterior fascia. Unlike other welding processes, it is not necessary to thicken wallstock in weld areas to prevent read-through with robotic laser welding of brackets on the backside of the part, and that reduces weight slightly. It also eliminates the need for contoured horns and punches. Clean cuts can be made in 1 sec on the painted side of the part. The dual-function process provides greater flexibility between programs and reduces floor space and tooling costs.

OEM/Vehicle General Motors Co. 2017 Chevrolet Camaro ZL1 System Supplier Magna Exteriors, Inc. Material Processor    Magna Exteriors, Inc. - DexSys

Material Supplier LyondellBasell Resin Hifax TYC1168X TPO Tooling/Equipment Supplier Jenoptik AG

For More Information See: http://www.plastics-car.com/Recycling-of-End-of-Life-Vehicles

TPO-Coated Suspension Arm

By using a cryogenically ground TPO powder coating to protect e-coated steel suspension arms instead of paint, service life is extended from 3-5 years to a decade, the fully encapsulated part gains improved stone-chip resistance and corrosion protection. Overspray can be reused, so the process generates almost zero waste, eliminates VOCs and isocyanates, and produces finished parts much faster than previous alternatives. Since there is no need for a post-bake process, it also saves energy. Thinner gauge, high-tensile steel is used for the suspension arms to save weight.

OEM/Vehicle General Motors Co. 2015 Cadillac ATS System Supplier Cymas Enterprises Ltd. Material Processor    Cymas Enterprises Ltd.

Material Supplier LyondellBasell Resin 7905 TPO

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Body-Exterior/Auto-Trim.html

Lightweight TPO Bumper Cover

A new, lighter weight TPO bumper cover was developed using high-crystallinity PP, ethylene-octane rubber, and a combination of nano-size talc and micron-size whisker fillers similar to magnesium oxysulfate.  The material provides high mechanical performance, improved dimensional stability, and low CLTE thanks to the high aspect ratio filler. Weight is reduced 7-10% and the material is cost neutral vs. the material it replaced. Additionally, 6 patents have been obtained on the development.

OEM/Vehicle Hyundai Motor Group 2017 Hyundai Genesis G90 System Supplier ECO Plastic Material Processor    ECO Plastic

Material Supplier Hanwha Total Petrochemicals Co., Ltd. Resin NB71 TPO Tooling/Equipment Supplier Hyundai Motor Company

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

Rhapsody Blue MIC Vehicle Environment

Project goals were to achieve a unique MIC color space that looks luxurious but appeals to today's generation. It involved using the first transparent pigment-based interior color deliverable across 76 base resins for the vehicle interior. Once the color was mastered, early attempts showed it was prone to metamerism with a red/green directional hue shift. Numerous attempts to achieve color consistency bidirectionally with standard pigment adjustments did not solve the problem. Finally, the color was remastered using a non-TIO2 system that did not exhibit hue shift, eliminating the need to paint and creating a calming, cool color environment.

OEM/Vehicle Ford Motor Co. 2016 Lincoln Continental System Supplier Americhem Inc. Material Processor    Many

Material Supplier Americhem Inc. Resin PP,TPO, ABS,PA, POM Tooling/Equipment Supplier Many

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

Low-Density Fascia Trim TPO

Through significant work at the molecular level, a new lower density (0.98 g/cm3) compounded TPO has been developed that meets all the stiffness, impact strength, dimensional stability, and melt-flow rate (MFR) requirements for automotive exterior body side moldings, rocker moldings, wheel flares, and fascias while reducing mass 5%, and cost ≈$1 USD /vehicle. Owing to its higher MFR, the material can be molded at lower temperatures, saving burden rate and shortening molding cycle times. It offers the same mechanical performance as the standard density TPO it replaced.

OEM/Vehicle General Motors Co. 2017 Cadillac XT5 & GMC Acadia System Supplier General Motors Co. Spring Hill Material Processor    General Motors Spring Hill Injection Molding North

Material Supplier LyondellBasell Resin Hifax 1168P TPO Tooling/Equipment Supplier Concours Mold, Inc.

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