IAC Presents Weight and Mass Reduction Initiatives at 2009 ITB Automotive Interior Conference

IAC expert to address lightweight strategies to improve fuel efficiency

DEARBORN, Mich., Sept. 24 -- International Automotive Components (IAC) will discuss strategies and solutions for weight and mass reduction at the 2009 ITB Automotive Cockpit and Door Conference today at the Sheraton Detroit Novi Hotel in Novi, Mich. Lee Childers, IAC vice president, Advanced Development and Tooling, will discuss IAC's strategy to help OEMs improve fuel efficiency, by addressing the challenges associated with designing components that help reduce vehicle weight. Childers' presentation is scheduled for 4:30 p.m.

"Weight reduction in vehicles continues to be one of the biggest issues facing interiors suppliers," said Childers. "At IAC, we have already achieved enormous successes in weight and mass reductions in vehicle interiors, but we are committed to continue developing new products, materials and technologies that can further reduce weight and impact fuel efficiency."

According to a study completed by the Environmental Protection Agency (EPA) and Bureau of Transportation Statistics, 75 percent of fuel consumption is directly related to vehicle weight, and EPA studies also have estimated that reducing vehicle weight by 10 percent saves seven percent of fuel at the pump. IAC's commitment to reduce weight and mass provides a potential weight savings total of more than 40 pounds in an average, midsize vehicle. Door panels, instrument panels, flooring and acoustics and headliners represent significant opportunities for weight reduction.

"With IAC's current potential weight savings approaching 50 pounds, we are working diligently with customers to provide solutions that confirm efficiency," said Childers. "IAC's continued product, material and technology developments will reduce costs, add value and offer intelligent fuel efficient solutions to vehicles of the future."

The most significant weight reduction opportunity is exemplified in IAC's flooring and acoustic segment with the use of bi-component fiber that combines different fibers (e.g. polyester and polypropylene) within the same filament. A 22 pound reduction could be achieved by using these recyclable, clean and environmentally-friendly fibers that remain a part of the structure, add integrity and offer a wide range of bonding temperatures for flooring and acoustics applications. Bi-component fibers technology also features improved sound absorption characteristics.

Additionally, part of IAC's lightweight strategy includes using natural fibers (e.g. jute, flax, kenaf, sisal and hemp) blended with polypropylene to configure door panels. With these two renewable materials, a one-step process is possible and together the materials create a low-weight, high-impact strength door panel. Potential weight savings in a door panel is nearly six pounds using these material solutions.

Lighter cross car beams, spray polyurethane skin and thermoplastic olefin (TPO) resin contribute to the weight savings opportunities available for instrument panels. A combined solution could reduce overall instrument panel weight by nearly nine pounds. The spray polyurethane skin delivers improved craftsmanship, provides an excellent performance and durability and supports the seamless passenger airbag design. The spray skin also has been approved and accepted by several OEMs. Additionally, using TPO resin reduces material density and improves performance while providing optimized weight and material performance.

In headliner applications, IAC offers several solutions that could have a potential weight savings of more than six pounds. These significant savings include new technologies for lightweight materials and replacing metal brackets with engineered resin for overhead lighting applications, all while providing additional design flexibility, greater rigidity and optimum system fit and finish.

ABOUT INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP

International Automotive Components Group is a leading global supplier of automotive components and systems, including interior and exterior trim and structural and functional applications. IAC operates manufacturing facilities in 17 countries with more than 24,000 employees and 2008 global annual sales in excess of $4.0 billion. For more information, visit www.iacgroup.com.