WINNER

Process / Assembly / Enabling Technologies - Entry 63

 

 

Bonded Hybrid Metal-Plastic Front End Carrier

 
OEM: Volkswagen
Model: Polo A05GP
Model Year: 2005
System Supplier: Simoldes
Molder / Processor: Simoldes
Toolmaker: Simoldes
Material Supplier: Dow Automotive
Generic Resin Type: GF PP
Resin Trade Name: Inspire/Betamate
Grade: DLGF9310.001ZB LESA 74030/74031
     
Summary:  The stiffness / weight ratio of the world's first bonded front-end carrier is maximized by adhesively bonding a metal reinforcement to an injection-molded thermoplastic-composite component. By bonding the parts together, stress concentrations are reduced on the composite part and the load is spread over the structure, enabling higher stiffness and load-bearing capacity. The metal is bonded to the long-glass-fiber polypropylene (LGF-PP) composite using a special 2-component acrylic adhesive, which has been designed to structurally bonds to low-energy substrates like PP without surface pre-treatment.

 

Finalist

Process / Assembly / Enabling Technologies - Entry 2

 

 

Integrally Molded HVAC Seal

 
OEM: Ford
Model: Lincoln
Model Year: 2006
System Supplier: Delphi Thermal and Interior
Molder / Processor: Carlisle Engineered Products
Toolmaker: Asis Co., LTD
Material Supplier: Washington-Penn
Generic Resin Type: 20% TF PP
Resin Trade Name: N/A
Grade: N/A
     
Summary:  An airtight seal for HVAC case joints has been created through the use of lateral compression of the split tongue, thus eliminating air leakage as cases separate under load, temperature, or pressure conditions. This robust sealing system enables the use of snap features to assemble the cases, since an airtight seal is maintained even with the over-travel clearance required to engage the snaps. The snap design also includes a unique case-to-case alignment feature.

 

Finalist

Process / Assembly / Enabling Technologies - Entry 7

 

 

Partial Mold-Behind Integrated Trim Panel

 
OEM: General Motors
Model: Chevrolet Impala
Model Year: 2006
System Supplier: Johnson Controls Inc.
Molder / Processor: Johnson Controls Inc.
Toolmaker: Viking Tool
Material Supplier: Basell Polyolefins
Generic Resin Type: PP
Resin Trade Name: ProFax
Grade: SD242
     
Summary:  This new process creates a one-piece trim panel that integrates multiple textiles in a single machine cycle. This replaces a multi-piece construction and heat-staking operations traditionally used. Tooling innovations include end-of-arm robotics, a fabric retention and placement mechanism, and a material interface/finishing ditch. The new process provides improved craftsmanship and product characteristics (BSR, long-term durability), and is environmentally friendly, reducing material usage, eliminating glue, and producing less waste.

 

Finalist

Process / Assembly / Enabling Technologies - Entry 46

 

 

Thick Sheet Thermoformed Exterior Trim

 
OEM: DaimlerChrysler / General Motors
Model: Jeep Renegade / Buick Lucerne
Model Year: 2005
System Supplier: Flex-N-Gate/Durakon Industries
Molder / Processor: Durakon Industries
Toolmaker: Tooling Technologies / Portage Casting
Material Supplier: EquistarChemical / Solvay Engineering Polymers / Soliant
Generic Resin Type: TPO
Resin Trade Name: N/A
Grade: PD907/E3000
     
Summary:  This is the first mass production of a “thick-sheet” paint film with Class A for exterior-trim panels. The material and process consistently meets the DOI and gloss requirements of painted parts, while providing 2x greater durability than paint. The component attaches to the vehicle with attachment features that are similar to those used with the previous injection-molded part. Weight and cost savings of 30% were achieved vs. injection-molded plastic appliqués.

 

 

Process / Assembly / Enabling Technologies - Entry 1

 

 

Balanced As-Molded HVAC Fan

 
OEM: General Motors
Model: W-Car
Model Year: 2003
System Supplier: Delphi Thermal & Interior Division
Molder / Processor: Delphi Thermal & Interior Division
Toolmaker: Delphi Thermal & Interior Division
Material Supplier: Basell Polyolefins
Generic Resin Type: PP
Resin Trade Name: ProFax
Grade: PDC1273
     
Summary:  The injection-molded heating / ventilation / air conditioning (HVAC) blower fan was engineered with reduced molding variability. This eliminated post-mold balancing of the motor and fan. The fan's rim design also reduces run-out variation and improves the burst strength of the fan blades.

 

 

Process / Assembly / Enabling Technologies - Entry 3

 

 

Headliner with Self-Reinforced Sunroof Opening

 
OEM: Nissan
Model: Maxima
Model Year: 2005
System Supplier: Lear Corporation
Molder / Processor: Lear Corporation
Toolmaker:  
Material Supplier: Azdel, Inc.
Generic Resin Type: LD-GMT
Resin Trade Name: Azdel Superlite
Grade: SL551000.101
     
Summary:  A secondary edge folding of the headliner cover is used to simultaneously heat stake the headliner substrate to itself, thus strengthening and improving the rigidity of the sunroof daylight opening (DLO). A low-density glass-mat thermoplastic (GMT) composite provides the thermoplastic substrate that makes this operation possible. This process eliminates the need for an inner reinforcing garnish ring (providing a vehicle savings of $1 / part) and provides a cleaner appearance. 

 

 

Process / Assembly / Enabling Technologies - Entry 4

 

 

TPV Upper Reveal Molding

 
OEM: General Motors
Model: Buick Lucerne
Model Year: 2006
System Supplier: Decoma International
Molder / Processor: Co-Ex-Tec
Toolmaker: Micro Mold
Material Supplier: ExxonMobil
Generic Resin Type: TPV
Resin Trade Name: N/A
Grade: N/A
     
Summary:  Heat-forming of multi-layer thermoplastic vulcanizate (TPV) extrusions allows the elimination of metal stampings and simplifies roll-forms typically used in a multi-piece assembly. Integrated appearance is achieved through elimination of plastic / steel joint. By eliminating the steel stampings, significant mass and cost savings are achieved. A co-extruded slip coat also eliminates secondary assembly operations.

 

 

Process / Assembly / Enabling Technologies - Entry 5

 

 

Sonic-Weld HVAC Dual Lock Valance-Panel Attachment

 
OEM: Ford
Model: Freestyle / Montego / 500
Model Year: 2005
System Supplier: Visteon Corporation
Molder / Processor: Toledo Mold and Die / Sarnamotive Blue Water Inc.
Toolmaker: Derby Manufacturing
Material Supplier: 3M
Generic Resin Type: PP
Resin Trade Name: N/A
Grade: N/A
     
Summary:  This is the first application of sonic welding to attach Dual Lock low-profile reclosable fasteners to valance panels. The process replaced the previous method of gluing the fasteners onto the PP substrate material, which required use of an adhesion promoter and a secondary cure cycle. An ultrasonic horn was developed and the material and process were refined so as not to damage the fastener stems during welding.