Critics Are Raving About the 'Art of a Part'
20 November 1998
Critics Are Raving About the 'Art of a Part' ... SPE Honors Automotive Industry's Most Innovative Use of Plastics
DETROIT, Nov. 19 -- Recognizing plastics' role in improving
vehicle safety, the Society of Plastics Engineers (SPE) - Automotive Division
has presented its Grand Award for the most innovative use of plastics to
Mitsubishi Motors for a composite bumper I-beam used on the 1999 Galant. The
plastic beam lowers vehicle cost and weight as it withstands 5 m.p.h. crash
and pole impacts without deforming to reduce vehicle damage and prevent
personal injury.
This and seven category awards for "the most innovative use of plastics"
were presented before 1,000 people attending SPE's 28th annual gala awards
dinner held recently at the Detroit Westin Hotel. Also, the SPE Board of
Directors presented a Special Recognition award to Volkswagen for its use of
polyurethane foam and other plastics in the new sub-compact Beetle. The
vehicle achieved top crash worthiness ratings by the Insurance Institute for
Highway Safety.
The theme of the evening was "Art of a Part."
"Normally, engineering is not considered an art form," said Bonnie
Bennyhoff, chairperson of the SPE Automotive Division. "But in using
plastics, the possibilities increase so exponentially that many engineers
today are developing almost an artistic sense to envision creative ways they
can improve vehicle component design."
The Awards Program winners, judged among 70 self-screened nominations and
27 finalists, are as follows:
High Impact Achievement -- I-Beam Wins SPE's Grand and Exterior Category
Awards
In replacing RF steel used by most auto manufacturers, the 1999 Mitsubishi
Gallant I-Beam, developed by Azdel, a joint venture between GE Plastics and
PPG, and compression molded by Continental Structural Plastics, is
35-45 percent lighter and offers cost-savings of up to 25 percent. This is
due to the glass mat polypropylene material and the design that integrates
mounting tabs for fascia and attachment stays that slide into the car's frame
rails. As a result, tooling and assembly costs are 20 percent lower. The
bumper beam does not permanently deform as steel can in absorbing energy to
meet the 5 m.p.h. federal safety and pole impact standard.
Plastic Engine Fan Meets the Test of Time and Enters SPE's Hall of Fame
Plastics were once considered less durable than metals. That notion
continues to be dispelled by SPE with an annual award for breakthrough
innovations in plastics that have "withstood the test of time." This year's
Hall of Fame Award was presented to the French automaker PSA for the first
engine fan of DuPont Zytel(R) nylon resin. Introduced on the Citroen DS19
sedan at the 1955 Paris Auto Show, the first integral nylon fan design reduced
cost by replacing 10 stamped metal parts and introduced thread-forming screws
as an attachment method for thermoplastics. Now used on virtually every car
in the world today, the plastic fan is more aerodynamic to improve engine
efficiency and reduces noise and part fatigue-failure versus previously used
metal fans.
Bumper to Bumper Closed-Loop Recycling Receives Environment Category Award
As a result of an innovative process by American Commodities, Inc. to
remove paint from plastic, the Milan and Utica plants of Visteon are able to
effectively recycle painted scrap parts and start recycling used (post-
consumer) TPO bumper fascia. The reclaimed material is reused in production
at blends ranging from 20 to 100 percent. Visteon is now recycling 1 million
pounds of painted TPO parts a year, which saves $250,000 in new material and
landfill disposal costs. Used for the first time in 1998, Visteon projects
that the innovative process will enable the benefits to increase four-fold in
1999 and lead to the eventual elimination of landfill disposal of TPO fascia.
Chassis Category Award Voting Results in a Two-Way Tie
Finalists in the chassis category were so competitive that even two votes
by the "Blue Ribbon Panel" of independent judges did not unlock a tie between
two innovations -- a steering column bracket support used on the 1999 Chrysler
NS van and the new General Motors truck clutch pedal and bracket assembly.
Steering Column Support Bracket
In replacing magnesium, the steering column support bracket is a first-
ever application for plastics. The demanding part, molded by InMold Corp.,
using DuPont Zytel(R) 70G33 glass reinforced nylon surpasses the previous
metal design in crash testing. In addition, part cost-savings for 750,000
units for Chrysler's Voyager and Caravan platform is $3 million a year plus an
initial $150,000 in tooling costs. Offering up to 10 percent in weight
savings, even compared to lightweight magnesium, the plastic bracket
eliminated secondary fastener attachments. In the future, Chrysler engineers
envision further part integration including a thermoplastic brake and
accelerator pedal box.
Clutch Pedal Assembly
The GMT800 (General Motors' C/K pickup truck) clutch pedal and bracket
assembly replaces stamped steel parts, offering a cost-efficient snap push rod
to pin assembly of the pedal and bracket by merely depressing the pedal when
it is installed on line. The assembly, a first in North America, is
manufactured by Florida Production Engineering using BASF's Ultramid(R) nylon
6 resin. Design advantages include a larger pedal bracket offset and
hexagonal molded attachment pins that eliminate the need for lash bushings and
fasteners that previously had to be applied on the assembly line. The molded-
in color nylon pedal assembly offers lower pedal movement free-play than metal
assemblies and a weight savings of 65 percent.
New Thermoplastic Wins Materials Category Award Due to Environmental and
Performance Advantages
Following eight years of research, Textron Automotive and Bayer Corp. have
commercialized an aliphatic thermoplastic urethane, called Texin(TM) DP7-3014.
In replacing PVC resins, it offers performance advantages for instrument panel
covers used on 1999 Chrysler Concorde and Chrysler LHS/Chrysler 300M models.
The new patented polymer does not use chlorine in its manufacture, reduces
window fogging, offers improved heat and UV exposure ratings and enables the
latest seamless passenger side air bag door design. Offering a leather-like
feel, the new thermoplastic is said to have improved scuff and mar resistance,
yet is applied using existing cast-molding skin equipment for IP
manufacturing.
Fully Integrated Air-Induction Module Wins Powertrain Category Award
Ford Motor Company will save more than $2 million a year in manufacturing
and assembly costs while it boosts performance for the 1999 Ford F350 light
truck with the 7.4 liter turbo diesel engine using a novel all-plastic
integrated air induction system. The module, developed and commercialized by
Visteon in under 12 months, incorporates an air cleaner tray and cover,
battery tray and cover, resonator and clean air tube at a 2.9 pound total
weight savings. One of the unique integrated functions of the module is to
pass clean air by the battery to keep it cool, thereby extending battery life,
without using separate air cooling ductwork. Other improved functions include
improved long-term durability and longer service intervals because the
system's design resists dust, water or snow ingestion. The nine-pound module
relies upon Ferro Corporation's polypropylene.
Appearance and Strength Highlights Body Interior Award for New Load Floor
A unique double-walled, blow molded polypropylene load floor and spare
tire cover for the 1999 Jeep Cherokee conceals the spare tire for greater
usable cargo space and a clean appearance. Compared to metal, wood and
injection molded plastic options, the single blow-molded part of Spartech(R),
PolyCom's 30 percent glass reinforced polypropylene, allows molded-in
attachments on the bottom side while preserving a smooth and flat show
surface. Carpet is loaded in an automated manner and is both molded onto the
show surface and trimmed within the 165-second total molding cycle. Because
of the double wall structure, noise and vibration are insulated, and the floor
can handle 250-pound loads at temperature extremes. Freemont Plastic Mold
designed the tooling, and Lear is responsible for supplying the final large
part to Chrysler.
A Disappearing Jeep(R) Door Frame Rail is the Process Category Award
Winner
Composite Products Inc. has developed a process for delivering Owens
Corning's 0.5- to 1-inch long glass fiber reinforcement and Montel's
polypropylene from the continuous material extrusion stage to compression
molding of the final part to maintain demanding performance requirements for
new Chrysler Jeep TJ soft-top door rails. The process disperses the long
glass fiber bundles into the resin without breaking them for optimum part
strength, appearance and lower costs. Mold actions form design features such
as a molded-in vinyl top retention strip and insert molded metal pivot pins
and fasteners with a final molded-in color grain surface. No secondary part
finishing is required.
This innovative process enables a unique door rail design, which is
inconspicuous when the top is folded down and can be folded and removed
altogether for storage in a small space. In addition, the design resolves
vinyl top fit, water leak and wind noise problems that have plagued other soft
top designs. Magna Decoma - Colorado supplies the finished part to Chrysler.