Trendsetters in automotive

 

The Automotive Division of the Society of Plastics Engineers (SPE®) revealed the winners for its 47th-annual Automotive Innovation Awards Competition, known as the oldest and largest recognition event in the automotive and plastics industries. The announcement was made on November 8, 2017 during the 47th SPE Automotive Innovation Awards Gala, held in Michigan, U.S.A. The award-giving body recognized the many innovations launched by key players in the automotive industry in tandem with leading companies offering high-performance materials and breakthrough technologies. 

 

The 2017 Grand Award was won in the body exterior category by the structural active grill shutter (AGS) with integrated loose layer construction of the 2018 Ford Motor Co. Ford Expedition luxury sport-utility vehicle (SUV) created by the partnership of Magna Plastcoat, Celanese and Integrity Tool. The material utilized was Celstran 40-20 PP GF processed through injection molding to create possibly the largest 2-shot AGS in production today. The product was designed with an integrated locating and attaching system for consistent fit between the grille and headlamps, eliminating the need for FEM assembly, dunnage and shipping. In addition to reducing variable and piece costs by an estimated $5 with an entirely thermoplastic solution, the enhanced design achieved $16 internal assembly cost reduction per vehicle and eliminated around $45 auxiliary costs by negating the need for a FEM.  As a result, Ford avoided an estimated $2 million in dunnage, assembly plant line and handling costs. Improved parts consolidation also phased out the need for four separate fasteners and associated labor.  Using LFRT technology to develop a structure with polypropylene offset an estimated 3 lbs. of weight over alternative metal and nylon hybrid designs considered. An equivalent steel structure would weigh 18 lbs. more than the LFRT design, which delivers the required durability. 

 

The Lifetime Achievement Awardee is Dr. Suresh Shah, retired, Senior Technical Fellow at Delphi Corporation, formerly General Motors – ACG (Automotive Components Group). Dr. Shah is a technical specialist, with over 30 years of experience and more than 45 Intellectual Properties including patents and trade secrets of which more than 40% of these are in production, by far more than the 4% industrial average. He advanced plastic processes including gas-assist injection molding, co-injection molding, microcellular molding, hybrid plastic/metal molding, direct (inline-compounded (ILC) long-fiber thermoplastic (D-LFT) composites and thin wall molding.  He also advanced material developments involving natural fiber composites, nanocomposites, thermoplastic polyolefins (TPOs) and thermoplastic elastomers (TPEs).  This expertise lead to several game changing innovations including the single piece, all plastic door hardware module known as SuperPlug, and TPO thermoformable skin for instrument panels.  He also developed many other innovative applications for exterior, interior and under-the-hood components.  His rare combination of expertise in materials, processes, part design and analysis; has earned him a reputation as one of the best problem solvers in the industry. 

 

The Hall of Fame recognition was given to  the thermoplastic polyolefin skin instrument panel in the 2000 General Motors Co. Pontiac Bonneville supplied by Inteva Products LLC (Delphi Interior Systems) in partnership with Mytex Polymers (formerly Exxon Mobil Chem. & Mitsubishi Chem. Corp. joint venture). The of TPO skin on IPs was recognized in the industry in 1999, when GM won the SPE® Most Innovative Use of Plastics Award in the Body Interior category. It improved safety by enabling air bag deployments, and reduced windshield fogging with the reduction of VOCs and odors without plasticizers and toxic stabilizers. The environmentally friendly all polyolefin system also enabled closed loop recycling and the replacement of PVC while reducing mass 10%.   

 

Future-generation parts unveiled

In the body interior category, the instrument panel carrier in the 2017 BMW AG Mini Countryman subcompact crossover utility vehicle (CUV) won. The part was produced by the team up of International Automotive Components (IAC), SABIC/Siebenwurst and Stamax PP LGF. Long glass fiber PP injection molding via structural chemical foaming with core-back process enabled the production of this part with very low VOC emissions, meeting VDA 278 specification. Extensive CAE work predicting warpage of the foamed part provided valuable insights, allowing for the modification of tooling in advance. Also, the use of foaming means less material is required resulting in a 15% weight savings, fewer emissions and less cost.

 

The chassis/hardware category recognized the powertrain mounting clevis bracket in the 2017 General Motors Co. Cadillac XT5 crossover sport-utility vehicle (SUV). Created by the team Hutchinson and BASF Corporation, the product was made of Ultramid A3WG10 CR BK00564 PA66+50%GF produced via injection molding. The engine clevis bracket is the first composite mount designed for a 6 cylinder engine, passing peak loads of 25 Kilo-newtons of force. The injection molded part replaces metallic solutions (stamping, welding and die-casting) used previously resulting in a 45% weight save.  NVH was also improved (reduction in cabin noise) due to the damping characteristics of the polyamide compared to aluminum. Corrosion resistance is improved and the part can be recycled at end of life.  Seven clevis brackets were developed for different powertrain combinations with no warranty claims after 1.5 years of production. 

 

In the environmental category, the next-generation sustainable content bio foam applied in the 2018 Ford Motor Co.  Ford Fusion sedan by the tandem International Automotive Components (IAC) and BASF Corporation with Elastoflex 3496/102 resin as chosen material. The application provides a sustainable alternative to conventional petroleum based foams -  at a lower weight and cost with more design flexibility. Caster based foam provides for lower molded density, the ability to be foamed in as little as 4 mm cross sections, and superior bond strength to mating materials. Foam in place tooling, where a cast PVC, TPE, or TPU skin is placed in the mold with a hard plastic retainer and the foam is injected between these two components, is used for processing.  A weight savings of 20 - 40% (depending on foam thickness) and a cost savings of $2 per average foamed in place instrument panel is achieved.

 

The low friction polymer for chain tensioner arms won in the materials category.  The material, Stanyl HGR2  PA46(+PTFE)  was processed through injection molding and installed in the 2017 Ford Motor Co.  Ford F-150 pickup and Ford Mustang sports car by the team of Borg Warner and DSM. The usage of a modified PA46 resin to enhance stiffness, on vehicles powered by a 5.0L V8 engine, was a drop-in replacement for PA66, for enhanced wear and friction performance. The resultant fuel economy savings (0.4%), from rotational torque reduction in the cam-shaft (0.5Nm), was equivalent to a 40lb weight reduction, and at 1/10th the cost. Annual environmental benefits include reduction in gas consumption by 12,000 Barrels and green-house gas emissions by 5,000 tons. This innovation is highly translatable, to provide affordable fuel economy improvement, and will be utilized on more Ford vehicles, beginning in 2018. The total potential environmental impact of translations across vehicle programs at Ford, may be multiple times the values noted for the Mustang and F-150.

 

The powertrain category  was won by the turbo charger outlet T-joint in the 2018 Hyundai Motor Co.  Genesis G80  and Kia Stinger sedans created by Hwaseung R&A Co., Ltd., Songwoo Industrial & Seji Solotech, Inc., and DuPont Korea Inc. A 42% weight and 35% cost reduction, and improved airflow reducing the pressure drop (-8kPa) to increase fuel economy and improve NVH performance was achieved by designing and molding this part with plastic compared to the previous aluminum die cast part.   Air flow noise was also reduced and long term durability increased via the rib pattern design. A new 35% glass fiber reinforced, heat stabilized polyamide 66 resin was developed for good retention of properties over time at temperatures up to 220 degrees C.

 

The category process/assembly/enabling technologies was won by the two-shot interior decoration bezel of  2018 Ford Motor Co.  Ford Fiesta subcompact. The team of Faurecia Interior Systems, Lotte Advanced Materials and JP Grosfilley SAS utilized INFINO LT1220 PC & Starex LX0760 ABS  through a two-shot injection molding to create a unique 3-D decorative effect. The effect  achieved with 2K 'reverse' injection molding (1st shot tinted PC) with overmolding of grained surface with 2nd shot (self colored pigmented ABS). This is the first time this process was used to achieve the 3-D visual effect (color and texture) for a part of this size and geometry. 

 

For the safety category, the Gen-3 4-way head restraint was the winner. Applied in the 2018 Ford Motor Co. Ford F-150 pickup, the partnership of Windsor Machine and Stamping with Ravago/Integrity Tool & Mold utilized Hylon N1000STHL PA. This low cost, low mass, head restraint provides exceptional rigidity for whiplash protection.  Using plastic, in place of steel, as the primary load bearing component is new to front row head restraints.   The part design eliminates manufacturing complexity making use of intelligent geometries so that readily available materials could be used.  A $10.73 million savings ($2.80/vehicle) is projected by the end of MY2020 as this technology is extended to new vehicle programs.

 

The vehicle engineering team award was won by General Motors Co. for its significant use of plastic on the 2018 Chevrolet Traverse. The team introduced a first surface appearance, thin wall, structural, long glass fiber polypropylene on the floor console carrier saving the program 30% mass or 2.2 lbs.  This eliminated the need for metal reinforcements to take $1.50/assembly out of the part as well; launched the first serial production polyamide clevis bracket reducing the part weight by 45% relative to the previous aluminum design while increasing damping by a factor of 10; developed a new LED headlamp system that includes 9 tailored elements – 9 individual lenses on top of nine 1x1 LEDs producing approximately 720 lumens.  These lenses include three large lenses (2 low beam / 1 high beam) coupled with six smaller ones (4 low / 2 high beam) and enabled lamp performance that is balanced with the customer requirements.; and extended the use of low density (0.96 g/cc) TPO on the front and rear fascias, wheel opening moldings, claddings and rocker moldings. The use of plastics and composites contributed to enhanced performance (8% power gain with the 3.6L V6), weight savings (7% lower than the previous program), improved fuel economy (17% increase) with best in class cargo space and up to 14 available advanced safety features.  

 

In the aftermarket category,  the award was received by the integrated floor bedliner divider in the 2017 General Motors Co.  Chevrolet Silverado pickup concept by Penda Corp. and Durakon in partnership with  A. Schulman where Polytrope TPP1026EU TPO  was utilized using twin sheet thermoforming. This first time twin sheet thermoformed bedliner divider is integrated into the bedliner as one piece. A $275 cost avoidance resulted by not having to manufacture a separate floor divider part.  The divider incorporates a molded in locking feature to secure the divider into the truck wall when it is raised.  It eliminates the need for a cargo net or separate divider allowing the customer to put smaller items in the bed without having the items move and slide around while the vehicle is in motion. Dual textures are achieved on both sides of the part and the design can be applied to different vehicle models and brands via an insert for different logos.