Delphi Introduces New Vehicle Interior Skin Technology

New Slush Cast TPO Skin Results in Low-Cost Interior Luxury

TROY, Mich., Aug. 25 -- Using breakthrough design and process technology, Delphi Corp. has created a new skin for instrument panels, consoles and other vehicle interior surfaces.

Delphi's Slush Cast Thermoplastic Polyolefin (TPO) Skin gives vehicle cabins a luxurious look and feel at a substantially lower cost than traditional sprayed urethane technology.

Slush Cast TPO Skin is the newest addition to Delphi's interior skin portfolio and is the best method for vehicles with complex styling features. Delphi continues to offer an array of interior skin materials and a variety of application methods to suit every type of vehicle style.

"This advancement in skin technology will have a significant impact on the future of automotive interiors," said Lon Offenbacher, business line executive, cockpits and interior systems and integrated closure systems, Delphi Thermal & Interior. "This high value innovation offers our customers, quite simply, superior appearance and performance at less cost than alternatives."

In 1997, Delphi was the first automotive interior supplier to introduce TPO in extruded-sheet form for use in the thermoforming process of instrument panel skins. Now, Delphi has developed a powdered form of TPO that can be used in a slush molding process.

The Material

TPO offers benefits beyond those of traditional polyvinyl chloride (PVC). TPO is highly recyclable and can be molded to color, which eliminates the need for painting. Its pliability prevents cracking and splintering in the skin when an airbag deploys in cold weather. Coupled with its ability to produce seamless tear seams, TPO is compatible with Delphi's hidden airbag door technology.

The Process

During the slush molding process, TPO is added to a heated mold in a powdered form. As the mold is rotated, the TPO melts and fuses to form the skin. The result is unmatched styling flexibility such as tight radii, undercuts and multiple grains, and easy skin enhancements like stitching, lettering, logos and grain definition. The overall surface feels better, has lower gloss and is more resistant to scratch and mar.

According to James Giardino, director of engineering, Delphi Thermal & Interior, to the company's best knowledge, there is only one other Slush Cast TPO product on the market today and it is significantly higher in cost and requires painting.

"This represents a significant accomplishment for our engineering team. Our research and development of TPO skin has made us a leader in this material and process technology," Giardino said.

Delphi's Slush Cast TPO Skin is scheduled to make its debut on a major 2008 North American sport utility vehicle.

Delphi presented a technical paper on the technology titled "Development of a Slush Molded TPO Instrument Panel Skin" at the Society of Automotive Engineers 2005 World Congress in April.

At Delphi, we help make cars safer, cleaner, more efficient, and fun to drive. For more information about Delphi Corporation, visit Delphi's Virtual Press Room at http://www.delphi.com/media .