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Summary: First sealed door module made with a material other than metal. Designed to maintain a water-tight seal while also carrying the load of numerous hardware components. Reduction in the total number of parts simplifies manufacturing.
Weight Savings: 12 lbs per 4 door vehicle due to parts elimination.
Cost Savings: Up to $5 per vehicle due to part elimination.
Most Innovative Feature: This is the first time that a sealed door module has been made with a material other than metal anywhere in the world.
Other Innovative Features: The part has been designed so as to maintain a water-tight seal while also carrying the load of numerous hardware components. This design reduces the total number of parts in the door and simplifies manufacturing.
Forming Process: This part was made via injection molding.
First time process used?: This is the first time injection molding was used to make a sealed module. All other sealed modules, being metal, use stamping.
Previous Process Used: The material is a long glass polypropylene pellet material from StaMax consisting of 30% glass content. The material is made via a wire-coating process. The long glass PP is then injection molded to form the door module. The material, being in a pellet form enables the part to be made via an injection molding process.
Tooling Innovations: No special tooling innovations were required. The fact that standard injection molding equipment is able to be used as a result of this material product form is actually unique in and of itself.
New Material Developments: Ford and Faurecia were able to benefit from this new long glass PP material in that it offers cost and weight savings vs. other materials while still meeting application requirements.
Weight Savings: Compared to conventional door systems which do not use a carrier at all, the use of the StaMax module can save over 12 lbs per 4 door vehicle due to parts elimination. The StaMax module can also be 50% or over 8 lbs per 4 door vehicle lighter than commonly used steel door module carriers found mostly on European cars.
Direct Cost Savings: Compared to a conventional door system in which no carrier is employed or even in comparison to commonly used steel modules, the use of StaMax module can offer a savings in direct costs due to parts elimination. Depending on the number of parts eliminated, the savings can be as high as $5 per vehicle.
Indirect Cost Savings: Due to a reduction in the number of parts, the OEM and Tier can realize indirect cost savings associated with fewer parts to be inventoried and a simplified manufacturing process. Therefore, indirect cost savings opportunities exist from a reduction in inventory holding costs, reduced assembly time, reduced floor space and even fewer warranty claims.
Direct Consumer Benefit: NVH characteristics of this material can be high performing versus metal due to the noise absorption properties of thermoplastics. Furthermore, consumers may experience fewer problems with their doors as the number of parts that can go wrong are fewer than in typical designs, thereby resulting in a reduction in warranty claims
Translates to other Vehicles?: This application can and is being translated to other vehicle lines, not only under consideration at Ford but also at other OEMs.
Safety Benefits: This module does not impact safety aspects of the door.
Environmental Benefits: Uncertain
Additional Info: This is the first sealed door module system to ever be made in the world with a material other than metal!
