Choice of SEQUEL(R) 1440 Thermoplastic Polyolefin Contributes to Performance and Economy of Innovative Fascia Design For New Ford Fusion Mid-Size Sedans

Engineering and testing resources of Solvay Engineered Polymers, Inc., help validate a cost-effective approach

MANSFIELD, Texas, Jan. 16 -- The 2006 Ford Fusion is the newest addition to the passenger-car lineup from the Ford Motor Company. Along with its siblings -- the Mercury Milan and Lincoln Zephyr -- the Fusion will fill the mid-size passenger car slot, fitting between the compact Focus and the full-size Five Hundred sedans.

Because this is the most competitive automotive segment in the United States, Ford engineers designed an innovative attachment scheme for the bumper fascias that would simplify assembly and help to minimize the total system cost of the fascias.

5-mph bumper impact performance

Front and rear fascias for the new Fusion sedan are injection molded of SEQUEL(R) 1440 thermoplastic polyolefin (TPO) from Solvay Engineered Polymers, Inc. The material has been developed to combine excellent impact resistance and stiffness. Ford had originally considered a less expensive material for this application, but the resulting parts did not meet the bumper-engineering group's expectations for low-temperature impact testing.

The selection of SEQUEL 1440 engineered polyolefin has provided the fascias with sufficient impact resistance so that the bumpers of all three models meet 5-mph impact standards, which is a Ford requirement for all its passenger cars. In addition to the upgrade in material technology, the Fusion's bumper-system engineers made some minor changes to the design of the rear fascia.

Making two living-hinge attachments work

Ford engineers had designed two integral tabs to attach the fascia to the bumper system. This attachment scheme was an economical approach to stabilizing the part under aerodynamic loads. Each tab featured a living hinge that allowed the tab to be bent back toward the attachment point.

Durability testing on the new rear-fascia design was conducted by Solvay Engineered Polymers (SEP) at its Applications Development Center in Auburn Hills, Michigan, using a gravelometer in a standard industry procedure. It demonstrated that continuous stone impingement at the bending point -- the thinnest part of the living hinge -- would lead to premature failure of the attachment tabs.

In a collaborative effort among engineers at SEP, Ford, and the molder, the tabs were re-designed to add an integral deflector that would prevent stones from striking the tab at its hinge point. Subsequent testing of the improved tab design showed that the new attachments could survive the original procedure without failure. Additional testing also showed that the hinge could remain intact after being subjected to nearly twice the abuse from gravel impacts.

Avoiding cost and complexity

Among the other advantages of selecting the SEQUEL 1440 material is its stiffness. The high flexural modulus enables the lower edges of the fascias to resist aerodynamic distortion or flutter that can result when the Fusion is traveling at highway speeds. This property of the SEQUEL TPO in a revised design let Ford avoid significant costs in achieving Ford's target for "firm feel."

Instead of using a stamped metal cross-car bracket to support the top shelf of the rear bumper fascia, the new Fusion fascia could be attached directly to the rear with the integrated tabs. The cost of the part is lower, and the assembly process is less complex. So, while more expensive than the material originally planned for the parts, the SEQUEL engineered polyolefin made a cost-effective contribution to the success of the Fusion's innovative fascia system.

Experience, resources, and global support

Solvay Engineered Polymers, Inc., is the leading supplier of thermoplastic polyolefin (TPO) materials and technology to the North American automotive industry, with significant sales to European and Asian carmakers. The company is headquartered in Mansfield, Texas, with sales and marketing operations and an Automotive Applications Development Center in Auburn Hills, Michigan. Its manufacturing, distribution, and research and development facilities are located in Mansfield and Grand Prairie, Texas, and in Shirley, Massachusetts.

The production and engineering operations of Solvay Engineered Polymers are certified to the standards of ISO/TS 16949:2002 for quality systems. More information about its products and capabilities can be found at http://www.solvayengineeredpolymers.com/ .

Solvay Engineered Polymers is a member of the Solvay Group, an international chemical and pharmaceutical group headquartered in Brussels, Belgium. The Solvay Group, whose companies employ about 30,000 people in 50 countries, recorded consolidated sales for 2004 of EUR 7.9 billion, generated by its three sectors: Chemicals, Plastics, and Pharmaceuticals. Solvay is listed on the Euronext 100 index of top European companies. Details are available at http://www.solvay.com/ .

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