|
|
Summary: Fully recyclable headlamp with improved aesthetics/styling based upon use of clear adhesive. Improved dimensional repeatability of lens to body by 43%. Improved process response time by a factor of 4X. In process scrap is reduce by 85%.
Weight Savings: None.
Cost Savings: $0.10 per lamp
Most Innovative Feature: A Fully recyclable Headlamp
Other Innovative Features: Improved aesthetics/styling based upon use of clear adhesive, Improved dimensional repeatability of lens to body by 43%, Improved process response time by a factor of 4X, In process scrap is reduce by 85%
Forming Process: Injection Molding using an Engel vertical injection molding machine with a rotary table to facilitate loading and unloading of the lens, body and final assembly.
First time process used?: Yes, This is the first application of this process. It is a patented/exclusive process to Visteon.
Previous Process Used: Previous method of manufacture was a two part urethane adhesive applied by robot, manually assembled, placed in a fixture and cured in an overhead conveyor.
Tooling Innovations: This application did not use any special tooling innovations. The mold is similar to many molds built for insert molding used in the injection molding industry.
New Material Developments: This application uses the same materials used to manufacture the body and lens.
Weight Savings: The weight of this product is virtually identical to the previous method of manufacturing. The adhesive has been replaced by the injected clear polycarbonate.
Direct Cost Savings: The estimated direct cost savings associated with this application is $0.10 per lamp
Indirect Cost Savings: The estimated indirect cost savings associated with this application is $0.04 per lamp
Direct Consumer Benefit: The consumer will see no direct benefit from this application. The consumer should not be able see any difference other than it can be reprocessed at the end of the vehicle's useful life.
Translates to other Vehicles?: This method of manufacturing can and will be used on future programs.
Safety Benefits: There are no significant direct safety benefits to using this process.
Environmental Benefits: This lamp is now completely recyclable. The lamp is made entirely of Polycarbonate and can be ground up and remolded into other components after the life of the vehicle is complete. The adhesive used to manufacture lamps the old way could not be reground and remolded because of the toxic gas developed at high temperature from the adhesive.
Additional Info: One of the most difficult hurdles to success for this process was finding a way to keep the decorative coatings off of the welding surfaces. We used the six-sigma process to find and develop the necessary manufacturing methods.
