(click on the images to see larger illustrations)
| Powertrain - Entry 39 |
WINNER |
|
| Oil Pan Module 2004 DaimlerChrysler Actros BR500 |
 |
|
| System Supplier: | KTSN | |
| Molder: | KTSN | |
| Tooling Supplier: | Hause Presswerkzeugbau | |
| Material Supplier: | BASF Corporation | |
| Resin: | Ultramid A3HG7 35% GFR PA66 | |
| Thermoplastic design allows for 30% more oil and extends the oil change intervals by 50% resulting in lower maintenance costs. Very complex tool design integrates many features into the molded part design. The plastic oil pan module is 1dB quieter than the aluminum module, and weighs 50% less. | ||
| Powertrain - Entry 21 |
Finalist |
|
| Transmission Oil Pan with Integral Filter 2005 BMW 7 Series |
 |
|
| System Supplier: | ZF GmbH | |
| Molder: | IBS Filtran & SPX Filtran | |
| Tooling Supplier: | IBS Filtran | |
| Material Supplier: | LanXess | |
| Resin: | Durethan AKV35 H2.0 PA66GF35 GF PA | |
| First successful plastic automotive transmission oil pan with integral lifetime filter element. Other benefits of this design include parts consolidation, reduced fluid aeration, ease of recycling, and improved acoustics. Provided a 40% weight savings versus comparable metal designs, and up to 18% cost savings. | ||
| Powertrain - Entry 34 |
Finalist |
|
| Oil Module with Plastic Housing 2005 Volkswagen Audi A3 / A6 |
|
|
| System Supplier: | Mann+Hummel USA, Inc. | |
| Molder: | Mann+Hummel USA, Inc. | |
| Tooling Supplier: | Fa. Schittelkop | |
| Material Supplier: | LanXess Corporation | |
| Resin: | Durethan AKV35SR1 H2.0 PA | |
| An all plastic housing replaces die-cast and machined aluminum for significant cost and weight savings. The plastic oil module integrates all the functions and provides an innovative automatic oil drain system. | ||
| Powertrain - Entry 53 |
Finalist |
|
| Charge Air Cooling Duct 2004 Ford Super Duty F-Series Truck |
 |
|
| System Supplier: | Casade Engineering | |
| Molder: | Casade Engineering | |
| Tooling Supplier: | Roush Industries | |
| Material Supplier: | DuPont Automotive | |
| Resin: | Hytrel Soft: 4275 Hard: 8539 TPE (TEEE) |
|
| In a first time metals replacement, a one piece air cooling duct with integral clamps reduced the total assembly from 7 metal pieces to 3 pieces total. The design utilized soft and hard durometer Hytrel in sequential coextrusion process to produce an airduct that is rigid enough to withstand high temperatures and pressures, while maintaining flexibility in other areas for sealing and engine movement. | ||
| Powertrain - Entry 20 | ||
| Engine-Mounted Mechanical Fan Shroud 2004 DaimlerChrysler RAM HD Pick-Up - Diesel |
 |
|
| System Supplier: | Sur-Flo Plastics | |
| Molder: | Sur-Flo Plastics | |
| Tooling Supplier: | Romeo Mold & Engineering, Inc. | |
| Material Supplier: | Solvay Engineered Polymers, Inc. | |
| Resin: | NexPreneŽ 1087A TPE/TPV | |
| The plastic ring with overmolded TPV allowed for a simple but elegant low cost solution to improve engine cooling. The materials used allowed for optimization of airflow and radiator coverage. The design significantly improved the durability for the fan/shroud system. | ||
| Powertrain - Entry 25 | ||
| Integrated Air Intake Module and Cylinder Head Cover 2004 Toyota/Daihatsu 1KR-FE CHC & PAIM |
 |
|
| System Supplier: | Toyoda Boshoku | |
| Molder: | Toyoda Boshoku | |
| Tooling Supplier: | - | |
| Material Supplier: | BASF Corporation | |
| Resin: | Ultramid B3WG6 BGVW GF PA6 | |
| This is the first air intake manifold integrated with the cylinder head cover using glass filled nylon. This unique integrated design allows for convenient in plant manufacturing process, and achieved a 30% weight savings versus aluminum. | ||
| Powertrain - Entry 28 | ||
| Long Life Filtration System 2005 Ford Focus |
 |
|
| System Supplier: | Visteon Coorporation | |
| Molder: | Visteon Coorporation | |
| Tooling Supplier: | - | |
| Material Supplier: | Ferro Corporation | |
| Resin: | HPP30GR20BK GF PP | |
| It is the first factory installed, zero maintenance engine air filter used in the automotive industry, utilizing a patented design combining a multi-layer polymeric filter media. The air cleaner is vibration welded shut to form the joint of the air cleaner halves. This creates a permanently sealed air cleaner. | ||
