Automotive Plastics Flex their Muscle
15 November 1999
Automotive Plastics Flex their Muscle ... Society of Plastics Engineers Honors Innovation Through the Power of Plastics
DETROIT, Nov. 12 -- The Society of Plastics Engineers (SPE) -
Automotive Division presented its Grand Award for the "most innovative use of
plastics" to DaimlerChrysler for the RITec(TM) Blow Molded Fan Shroud
Assembly. The component was introduced on the 2000 Dodge Durango/Dakota. The
blow molded process and assembly helped reduce manufacturing costs by
integrating five parts into one and delivering a 1.2 lb. weight reduction per
vehicle.
The Grand Award and seven category awards for "the most innovative use of
plastics" were held November 11 at the Detroit Marriott. The theme of the
evening was "The Power of Plastics."
"Automotive plastics have proven their durability in high-stress
automotive applications," said Suresh Shah, chairperson of the SPE Automotive
Division. "But their power comes from the modular car design possibilities
that improve fit and function and lower costs."
The Awards Program winners, judged among more than 70 self-screened
nominations and 23 finalists, are as follows:
Blow Molding Consolidates Assembly - RITec(TM) Fan Shroud Wins Grand,
Process and Enabling Technologies Awards
Making the switch from traditional injection molding to blow molding, the
RITec(TM) Fan Shroud and Reservoir Assembly for the 2000 Dodge Durango/Dakota
has consolidated five components including: radiator fan shroud; coolant
reservoir; front washer reservoir; rear washer reservoir; and rear washer
reservoir fill funnel. This component integration saved engine compartment
space, eliminated a number of fasteners, reduced assembly floor space and
time, while eliminating shipping costs for the integrated components. McCord
Winn Textron supplied the assembly that eliminated 1.2 lb. per vehicle and is
expected to provide millions of dollars in overall cost savings. The part is
molded from Montell Profax SD613 polypropylene with tool and process design
from Hobson Mould Works, Inc, Shell Rock, IA.
Pre-filled Clutch Hydraulic System Enters SPE's Hall of Fame
A pre-filled clutch hydraulic (PFCH) system that debuted on the 1982 Ford
Ranger has received the Trav Meister Hall of Fame Award. The system has a
long history of SPE innovation, having captured a nomination in 1982, the
powertrain award in 1991 and another powertrain nomination in 1993 for the
concentric slave. Produced by Automotive Systems (USA), Inc., the system,
which is still in use today, offers simplified assembly with fewer parts to
inventory, store, order and manage. Molded from DuPont Zytel(R) nylon PA66
GF43, the PFCH also offers improved noise reduction, high load and travel
efficiency, consistent smooth operation, and shock load reduction.
Recycled Tires are Turned into Thermoplastic Elastomer Seals - to Win the
Environment Category Award
Responding to the growing demand for recycled content in automotive
materials, NRI Industries developed Symar-T, a hybrid polyolefin-based
thermoplastic elastomer, containing up to 60% post-consumer, tire-derived
rubber. Used on the lower radiator seal on the 1999 Jeep Grand Cherokee,
Symar-T has proven itself to be a versatile and cost effective alternative
that contributes to environmental and recycling efforts. The development of
Symar-T radiator seals offers a unique combination of rubber and plastic
performance that cost effectively manages cooling airflow and improves grill
appearance. Current use of Symar-T at 3,375,000 lbs. per year, removes
150,000 scrap tires from landfill waste.
2000 Ford Focus Grille Opening Reinforcement Claims Chassis Category Award
Originally developed and launched in Europe, the GOR (Grille Opening
Reinforcement) of the 2000 Ford Focus incorporates hybrid technology to
provide structural support of the front-end while integrating numerous
functions. The original GOR concept included more than ten metal components
that were to be welded together. Investigations revealed that this solution
would not meet the necessary dimensional tolerance requirements. Ford and
systems supplier Visteon used plastic/metal hybrid molding and development
technology from Bayer to optimize integration of parts and functions. The
project was supported by toolmaker Misslbeck.
Molded-in-Color Application Takes a Shine to the Innovation in Materials
Award
DaimlerChrysler received the Most Innovative Use of Plastics Materials
Award with a revolutionary new material for the molded-in-color bumper fascia
on the 2000 Neon. The fascias were injection molded from the Surlyn(R)
Reflection Series(TM) Supergloss Alloy produced by DuPont and offered in
partnership with A. Schulman. Build-A-Mold designed the polished tools. The
alloy offers superior color matching, scratch and mar resistance and high-
gloss appearance. By eliminating painting and transportation, significant
environmental and cost saving benefits were achieved. In addition to SPE
honors, the part was also recognized for its environmental accomplishments
with DaimlerChrysler's prestigious CHEER award earlier this year.
Active Intake Manifold Incorporates Plastic Flaps, Wins Powertrain
Category
The active air intake manifold on the BMW Rover uses plastic flaps to
control air flow for the most efficient engine operation at high and low RPMs.
The manifold offers reduced complexity while delivering significantly more
torque than the passive aluminum manifold it replaces. Molded by MANN+HUMMEL,
the manifold is produced from DuPont Zytel(R) 70G35HSL nylon. A patented
overmolding process allows two different materials for the flap and frame to
be injection molded one after the other, eliminating the need for further
assembly. The switch from aluminum offered the automaker a weight reduction
of 50 percent and a cost reduction of 30 percent.
It's What's Inside That Counts: Soft TPO Skin Instrument Panel Wins
Interior Award
A soft TPO skin that is featured on the 2000 Pontiac Bonneville is the
first in North America to be used for full instrument panel design instead of
PVC. Supplier Delphi Interior Systems with support from toolmaker D&E Corp.
molded the component from Mytex AN 13K-05 TPO produced by Mytex Polymers. The
TPO skin also will provide more than 10 years durability with no crazing or
color fading, outstanding cold weather air bag deployment and a weight savings
of 10 percent. The process also uses a waterbased coating system to control
VOC plant emissions.
Smart Body Panels with Clearcoat Captures Body Exterior Award
The 1999 DaimlerChrysler Smart Micro Compact Car (MCC) sold in Europe
features the first ever application for interchangeable molded-in-color body
panels. Supplied by Dynamit Nobel and molded from GE Plastics Xenoy (MIC),
the panels offer fashionable color choices that allow drivers to express their
personality or do-it-yourself repair. The functionality of the panels
includes high impact strength for dent resistance, reduced fuel consumption
due to 50 percent weight reduction, and inherent corrosion resistance. The
molded-in-color part with clearcoat provided by the molder, eliminates the
paintshop step from the vehicle's production, cutting costs for the automaker.