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 Thermoplastic Composite
Headliner |
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| Application Description: First PP-GF composite based headliner used in commercial application in North America. | Single Most Unique Feature: The most unique feature of this headliner is its high rigidity over a wide temperature range. The 48" x 90" headliner weighs only 6.2 lbs. with energy absorbing pads. |
| Process Descriptions: Thermo-stamping at low pressure (30-75 psi). | First Usage of Process?: This process was used for the first time in North America. |
| Formerly Used Process: The material used previously was polyurethane. PU required 3 processes to produce headliners compared to two processes using this new material. | Tooling Innovations: No special tooling was required, but the entire manufacturing process is unique. |
| Material Innovations: AZDEL, Inc. developed the AZDEL SuperLite material for this application. | Mass Savings: AZDEL SuperLite headliner assembly is 35% lighter than comparable PU headliner assemblies |
| Cost Savings: 5% cost savings in materials and 30% cost savings in cycle time. | Cost Avoidance: This application eliminates one additional manufacturing step compared to PU headliner manufacturing. |
| Direct Consumer Benefit: This material has comparable or slightly better acoustic properties than PU. It also provides greater styling flexibility, more headroom and allows recessing of components with less gap width. | Is Technology Transferable?: This application has been translated to four other applications and 6 new applications will start globally next year. |
| Significant Safety Benefit: This material has no environmental issues due to odor or emission and in higher density, can meet the FMVSS 201 requirements with no additional countermeasures. | Significant Environmental Benefit: No odor or VOC emissions during manufacturing of the material or the headliner. |
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Multi-Ply Construction |
