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Environmental - Entry 46


Fan and Shroud Module
2005 General Motors GMT 800/900 Light Trucks
System Supplier: Robert Bosch Corp.
Molder: Robert Bosch Corp.
Tooling Supplier: Cavalier Tool/Galaxy Tool
Material Supplier: Wellman, Inc. 
Resin:  Wellamin Ecolon 2000 PA
This is the first electrically driven fan & shroud to replace engine driven fans and shrouds on light trucks. This design increases fuel efficiency & horsepower while reducing cost at GM. The material used is recycled post consumer mineral/glass nylon developed for improved processing, improved surface appearance, and lower cost.


Environmental - Entry 41


Co-Extruded Hood to Cowl Seal
2005 DaimlerChrysler KJ Jeep Liberty
System Supplier: Jyco Sealing Technologies
Molder: Jyco Sealing Technologies
Tooling Supplier: Jyco Sealing Technologies
Material Supplier: Advanced Elastomer Systems 
Resin:  Santoprene 9103-45 TPV
The TPV carrier section of the cowl seal replaces metal on the conventional EPDM cowl seal and introduces unique mechanical lock retention feature. Achieved a 30% weight savings and approximately 25% cost reduction. This part also eliminated the need for a secondary anticorrosion coating. 


Environmental - Entry 43
Instrument Panel Laminate Materials Recovery
2005 Ford Taurus

System Supplier: ACI Wipag
Molder: Visteon Corporation
Tooling Supplier: None 
Material Supplier: ACI Wipag 
Resin:  DYLARK 480P20 SMA & PC/ABS
The Laminate Materials Recovery Process separates to very high purity level the three laminate components typically found in foam & skin instrument panels: substrate, foam and skin. The recycled material offers 30-50% cost savings versus virgin material, and had prevented the land filling of over 400 million pounds of material. 


Environmental - Entry 55
Modular Loadfloor System
2005 DaimlerChrysler Jeep Grand Cherokee
System Supplier: Venture
Molder: Venture
Tooling Supplier: Venture
Material Supplier: Eleison, Inc.
Resin:  Sandwiform Structural PP
This mono-material application makes significant consideration of recycling in its design and manufacture. It uses reprocessed load floor offal back into new load floors, and post-industrial and post-consumer polymers in skins used in the honeycomb load floor. Many components were redesigned to allow use of PP for the majority of the components. Unique design includes living hinges, in-mold decorating, and a flip lid formed in the same loadfloor process.