3D Flocking Tape on Inner & Outer Belt

This 3D flocking tape cell applies flocking tape to the bi-injected TPE/PP outer belt using a 6-axis robot. For optimal performance, the process requires multiple adjustments, including speed, contact pressure, heat, and proper guidance. It is able to meet general tolerances of ± 1 mm and CLD client requirements. Benefits of the process include reduction of secondary operations, eco-friendly recyclable part, design flexibility vs. extrusion, reduction in weight (10-15%) and cost (≈25%), reduction of labor, and cosmetic and performance improvements. The flocking tape facilitates sliding across 3D parts.

OEM/Vehicle PACCAR Inc. 2015 Kenworth System Supplier Hutchinson Group Material Processor    M.I. Integration

Material Supplier Rhetech / ExxonMobil Chemical Resin Rhetech T20P100 PP Santoprene 121-70M350 TPV Tooling/Equipment Supplier M.I. Integration

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

Grill Opening Reinforcement & Shutter Body Assembly

This application features a unique sealing system integral to the structural support system, which consists of a plastic-metal integrated shutter body plus grill opening reinforcement assembly. Use of two-shot injection molding creates a single part with a hard PP structural reinforcement and a soft TPV for proper sealing to the mating surface.

OEM/Vehicle General Motors Co. 2015 Cadillac Escalade SUV System Supplier Kirchhoff Van-Rob Automotive Material Processor Shape Corporation

Material Supplier RheTech & Teknor Apex Co. Resin RheTech GC45P100-01 PP Sarlink 4765B TPV Tooling/Equipment Supplier             Precision Mold & Tool

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

Instrument Panels with Injection-Molded Skin

This is the world's first instrument panel featuring an injection-molded thinwall skin in ultrahigh-flow TPV (meltflow rate of 250 g/10 min).  Thanks to excellent mechanical properties, the 1-mm skin could accommodate deep draws and uneven undercuts, providing new levels of design and styling. The material provides superior visual appeal, distinctive elongation, and softer touch preferred by consumers without compromising airbag deployment. Versus PVC slush molding, the TPV provides good long-term appearance and gloss levels, molds in just 60 sec, is 25% lighter and 10% less costly.  Tooling costs are lowered and scrap is reusable.

OEM/Vehicle Nissan Motor Co. 2013 Sentra compact car System Supplier Calsonic Kansei Corp. Material Processor Calsonic Kansei Corp.

Material Supplier Asahi Kasei Chemicals Resin SUNVIEO A7171 TPV Tooling/Equipment Supplier Calsonic Kansei Corp.

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

High-Lubricity Fuel Filler-Door Seal

This slip-modified, high-lubricity TPV with 10% siloxane has a soft durometer (45 Shore A) and is uniquely formulated for fuel filler-door seals to allow easy opening/closing force under all required environmental conditions. The TPV is bonded via 2-shot injection molding to a 20% GR PP substrate. The previous TPV door seal was 55 Shore A durometer, making it hard to open/close the filler door (requiring an 80 N force). The new TPV reduces opening/closing force to 38 N, so less effort is required to operate the door, providing ergonomic benefit to consumers. It was a drop-in replacement so no part-design changes were needed.

OEM/Vehicle General Motors Co. 2014 Cadillac CTS luxury sedan System Supplier US Farathane Material Processor US Farathane

Material Supplier Mitsubishi Chemical Performance Polymers Resin Trexprene A45SBW/SCW TPV Tooling/Equipment Supplier Proper Tooling

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

Direct Extrusion of Bulb Seal on Cowls

By directly extruding a bulb seal onto an air-inlet panel (cowl), the application's functional requirements are met and time-consuming manual installation of the seal is eliminated as a secondary operation.  An extrusion die, mounted to a flexible, heated hose and guided by a robot, quickly and efficiently lays down a TPV profile along the edge of the injection-molded substrate.  The fully automated process creates an easily tunable and functional seal that can be handled immediately after extrusion without need for post cure (as with thermoset rubber).  The operation is cost-effective, eliminates a secondary operation, maximizes sealing to the hood interface with excellent dimensional stability, reduces scrap, and provides high design freedom and process flexibility.

OEM/Vehicle Ford Motor Co. 2013MY Ford C-Max System Supplier Windsor Mold Group Material Processor Windsor Mold Group

Material Supplier ExxonMobil Chemical Resin Santoprene 121 50E500 TPV Tooling/Equipment Supplier Reis Extrusion GmbH

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

Glass Run Channel

This is the first sliding door glass run channel for a minivan with an all-plastic sealing and retention structure, and the first time TPV has been used for this type of door without metal reinforcement.  This fully recyclable TPV extrusion is produced with inline cutting and injection molding processes, reducing mass by 30% and cost 20-30% vs. the previous technology.

OEM/Vehicle 2007 Chrysler ® Town & Country / Dodge ® Caravan minivans by Chrysler LLC System Supplier JYCO Material Processor JYCO

Material Supplier DSM Resin Saralink ® highly cross-linked TPV Tooling/Equipment Supplier JYCO

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

Low-Profile Outer-Belt Weatherstrip

The outer-belt weatherstrips on the 2010MY Ford Taurus sedan are industry’s first to provide a low-profile, tri-extrusion with stainless steel, TPV, and a high-gloss vinyl ionomer. The manufacturing process envelope was pushed to the maximum to satisfy the Taurus design theme, achieving a functional component that offers three different textures (low-gloss, high-gloss, and stainless) in the same part.

OEM/Vehicle 2010MY Ford Motor Co.: Ford®  Taurus® Sedan System Supplier Cooper-Standard Automotive Material Processor Cooper-Standard Automotive

Material Supplier ExxonMobil Resin Santoprene® TPV

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

Roof Ditch Molding

Two-shot rotational molding was used for the first time to produce this roof-ditch molding, eliminating 100% of the assembly labor while providing significantly improved craftsmanship.  Use of 40% LFT-PP in this application yielded a stiffer part than the aluminum it replaced, leading to more consistent fit with the exterior sheet metal.  An overmolded TPV seal was customized to improve bonding to the PP substrate. Weight was reduced 15% and cost is 55% lower, saving the OEM $1.2 million USD annually.

OEM/Vehicle Ford Motor Co. 2011 Ford F150 System Supplier SRG Global, Inc. Material Processor SRG Global, Inc.

Material Supplier Multibase & A. Schulman Resin TPV / PP Tooling/Equipment Supplier Proper Mold & Engineering Inc.

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

Multi-Functional Exchange Blow Molding Airduct

This multi-functional-exchange blow-molded air duct integrates the resonator, brackets, and pipe in a single step using a combination of hard PP / soft TPV resins via a new process.  The part replaced a combination of rubber hose, metal and resin ducts, the resonator, and clamps with a single part produced in a single process step where material change, wall thicknesses, and inner pressure are all controlled very precisely.  The application saved an estimated 30-40% in weight and 25-35% in both direct and indirect costs.

OEM/Vehicle Subaru 2010 Legacy & Outback System Supplier Excell USA Inc. Material Processor Excell USA Inc.

Material Supplier Channel Prime Alliance & ExxonMobil Chemical Resin Marlex AMN-010 PP Santoprene 101-73 TPV Tooling/Equipment Supplier Excell Corp.

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

Power Liftgate Anti-Pinch Sensors

A conductive grade of TPV is used for the first time in power lift gate anti-pinch sensors.  The co-extruded TPV material, with a wire core inner, replaced thermoset EPDM rubber, which tends to harden over time as well as exhibit surface blooming, chalking, and cracking.  The TPV solution offers superior long-term surface aesthetics while meeting flexibility and performance requirements.

OEM/Vehicle 2004 MY Nissan Motors Nissan® Quest / Armada System Supplier Nicholas Plastics, Inc. Material Processor Nicholas Plastics, Inc.

Material Supplier ExxonMobil - Advanced Elastomer Systems Resin Santoprene® 121-50 Olefinic TPV Tooling/Equipment Supplier Nicholas Plastics, Inc.

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

Passenger Airbag Door / Chute System

This application is an all-thermoplastic passenger airbag door, replacing a steel bracket previously used to support the door during airbag deployment. The TPV chute is vibration welded to the backside of the decorative door, which is decorated using a film applied in-mold.  This design resulted in over a 20% weight savings, and assembly cost reduction.

OEM/Vehicle 2006 MY DaimlerChrysler PT Cruiser System Supplier Cadence Innovation Material Processor Cadence Innovation

Material Supplier Solvay Engineered Polymers Resin Sequel® 2326 TPO with Paint Film NexPrene® 1087A TPV Dexpro® 515 TPO Tooling/Equipment Supplier Cadence Innovation

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