| Description |
|
Plastic Composite Iron Ignition Cores |
| OEM, Model, Model Year |
|
General Motors, Opel Astra, 1992 |
| System Supplier, Contact, Phone |
|
Delphi Automotive, Thom Reddington, (756)646-2223 |
| Molder/Processor, Contact and Phone |
|
Delphi Automotive, Bill Micheal, (856)829-2220 |
| Toolmaker |
|
Toolco |
| Material Supplier, Contact and Phone |
|
GE Plastics, Tim Rash, (812)831-4829 |
| Generic resin type |
|
PEI |
| Resin Trade Name |
|
Ultem |
| Grade |
|
1000 |
| Nominated by, Company |
|
David Gay, Delphi Automotive |
| Address |
|
8750 Hague Road, Indianapolis, IN 46256 |
| Phone |
|
(317)579-3735 |
| Fax |
|
(317)579-4991 |
| Email |
|
david.gay@delphiauto.com |
| Summary | | Plastic coated iron power is molded into an unsintered, net shape part with high density and strength. These parts replace laminated cores for AC electromagnetic cores such as ignition or stator cores. The plastic insulation layer on each particle isolates the eddy current losses. Weight Savings: None Cost Savings: $5 million over 10 years Cost Avoidance: Parts reduction, design flexibility. |
| Most Innovative Feature | | Net shape manufacturing to replace laminations in AC electromagnetic applications |
| Other Innovative Features | | Coating iron powder with plastic layer to isolate molded part to isolate for EDDY current losses |
| Forming Process | | Microencapsulation and uniaxial compression molding |
| First time process used? | | Yes - in Portugal in 1990 |
| Previous Process Used | | Metal sheet laminations, stamping, welding |
| Tooling Innovations | | Warm pressing and powder heating |
| New Material Developments | | Studies to utilize soluble, high temp melt flow material |
| Direct Cost Savings | | $5 million over 10 years |
| Indirect Cost Savings | | Parts reduction, higher efficiency, design flexibility |
| Direct Consumer Benefit | | Smaller package, higher energy, lower temperature operation |
| Translates to other Vehicles? | | Yes |
| Environmental Benefits | | Newer formulations eliminate Methylane Chloride usage |