| Description |
|
Sub-frame, Gear Box Support Bracket |
| OEM, Model, Model Year |
|
Volvo, V70 AWD, 2000 |
| System Supplier, Contact, Phone |
|
Alcoa D-73730 Esslingen , Mr.Reiner Keller, (711)930-2261 |
| Molder/Processor, Contact and Phone |
|
Polytec SA , Ulf Wernström, (463)726-7584 |
| Toolmaker, Contact and Phone |
|
Swepart Verttyg AB, Tüve Johansson, (454)945-61 |
| Material Supplier, Contact and Phone |
|
Quadrant Plastic Composites AG, Gerry Battino, (248)374-1862 |
| Generic resin type |
|
PP |
| Resin Trade Name |
|
Symalit GMTex |
| Grade |
|
1:1/45° |
| OEM Engineer, Title and Phone |
|
Lars Persson S-40508 Gothenburg, Ing. Program Engineer, (317)650-425 |
| Nominated by, Company |
|
Gerry Battino, Quadrant Plastic Composites |
| Address |
|
Hardstrass 5, PO Box CH-5600, Lenzburg, Switzerland |
| Phone |
|
(248)374-1862 |
| Fax |
|
(248)374-1863 |
| Email |
|
gerald.battino@qplas.com |
| Summary | | Unique design uses reinforced thermoplastic material and design for the replacement of an aluminum structural member which carries the gear box. Product designed to survive the high bending and torsional loads under relatively high temperatures. Weight Savings: 930 grams vs aluminum die casting Cost Savings: Significant Cost Avoidance: Elimination of the corrosion-resistant coating on the the aluminum part plus the cost of the tooling and machine center for secondary machining. |
| Most Innovative Feature | | The use of a glass reinforced thermoplastic material, and the application design, for the replacement of an aluminum structural member on an SUV which carries the gear box. |
| Other Innovative Features | | The material was designed to survive the high bending and torsional loads under relatively high temperatures. The part provides weight and cost savings along with the elimination of corrosion that occurs on the former aluminum part. |
| Forming Process | | Thermoplastic compression flow molding |
| First time process used? | | Yes |
| Previous Process Used | | An aluminum casting which required secondary machining operations for the holes and the mounting surfaces and an application of a corrosion resistant coating. |
| Tooling Innovations | | Internal punches within the mold are used to form the attachment holes, so that there are no secondary operations needed. |
| New Material Developments | | A woven mat, in +/- 45°, is combined with random continuous fiber GMT mat. This combination provides very high properties in selected areas as well as flowability. |
| Weight Savings | | 930 grams weight savings versus aluminum die casting |
| Direct Cost Savings | | The cost savings for the elimination of all machining operations on the aluminum casting are not available. |
| Indirect Cost Savings | | Elimination of the corrosion-resistant coating that was used on the aluminum part plus the cost of the tooling and machine center for secondary machining. |
| Direct Consumer Benefit | | Noise dampening is reported to be better plus the advantage of reduced weight. In addition, part durability has been tested and shown to provide a life cycle of 3 times greater than the previous aluminum part. |
| Translates to other Vehicles? | | This application can be translated to similar parts. |
| Environmental Benefits | | GMT materials use less primary energy per kg compared to aluminum or steel. |
| Additional Info | | This part justifies the use of thermoplastic GF materials, based on PP resins, for many other similar structural applications. |