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| WINNER |
Body Interior - Entry 12 |
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HVAC Film Valve |
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| OEM: | General Motors | |
| Model: | Pontiac Grand Prix | |
| Model Year: | 2004 | |
| System Supplier: | Delphi Corporation | |
| Molder / Processor: | Macauto Industrial Co., Ltd. | |
| Toolmaker: | Macauto Industrial Co., Ltd. | |
| Material Supplier: | Saint Gobain PPL | |
| Generic Resin Type: | PTFE/Fiberglass/Silicone | |
| Resin Trade Name: | N/A | |
| Grade: | N/A | |
| Summary: A highly flexible, plastic film valve with apertures is moved within a housing to precisely meter airflow within a very confined space without stratificating hot & cold airstreams. The composite "film" is made of polytetrafluoroethylene (PTFE) and silicone rubber reinforced with fiberglass. For manufacturability, a unique plastic snap-fit spring-loaded pin / bearing assembly was developed. The film valve offers 13 thermal settings for improved passenger comfort. The tensioning system results in superior anti-rattle & anti-vibration characteristics. Air rush noise is reduced because the valve does not "rudder" through the air stream, which would otherwise create turbulence. | ||
| Finalist |
Body Interior - Entry 35 |
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Expanded Polypropylene Seat Base |
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| OEM: | General Motors | |
| Model: | Chevrolet Impala | |
| Model Year: | 2006 | |
| System Supplier: | Lear Corporation | |
| Molder / Processor: | JSP International | |
| Toolmaker: | Schraml Metalworks | |
| Material Supplier: | JSP International | |
| Generic Resin Type: | EPP | |
| Resin Trade Name: | Arpro | |
| Grade: | N/A | |
| Summary: This expanded polypropylene (EPP) seat system allows for a thinner profile assembly, yielding significant systems weight savings. The thin profile allows the seat to flip up with a hinge mechanism inserted into the EPP core component. This unique application also allows storage of components under the seat during vehicle travel. The seat is 100% recyclable within existing waste-stream recovery systems. | ||
| Finalist |
Body Interior - Entry 64 |
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Seamless Passenger Airbag Lid |
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| OEM: | Honda | |
| Model: | Civic | |
| Model Year: | 2006 | |
| System Supplier: | Takata Restraint Systems, Inc. | |
| Molder / Processor: | Visteon - Carplastic Plant | |
| Toolmaker: | Build A Mold | |
| Material Supplier: | Mitsubishi Chemical | |
| Generic Resin Type: | TPO | |
| Resin Trade Name: | N/A | |
| Grade: | AP15 | |
| Summary: This is the first application of a laser-scored, integrated seamless topper-pad lid where the topper lid is made by injection molding directly into a soft TPO skin. The soft topper pad is made of olefinic materials and is fully recyclable. Multi-cavity thermoforming of the TPO skin reduces manufacturing costs. The topper pad provides an excellent soft feel, an integrated passenger airbag (PAB) lid appearance, and good deployments without the costs associated with high-end, soft composite topper-pad manufacturing. | ||
| Finalist |
Body Interior - Entry 66 |
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In-Mold-Coated, Injected PUR Skin |
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| OEM: | DaimlerChrysler / Mercedes | |
| Model: | S-Class & SLK | |
| Model Year: | 2004 | |
| System Supplier: | Faurecia Interior Systems | |
| Molder / Processor: | Faurecia Interior Systems | |
| Toolmaker: | Frimo Sontra | |
| Material Supplier: | Elastogran, BASF, ISL | |
| Generic Resin Type: | PUR | |
| Resin Trade Name: | Elastoskin | |
| Grade: | I4639/107 | |
| Summary: The combination of in-mold coating (IMC) and polyurethane (PUR) injection results in a two-component material composition with good design flexibility, fully reproducible 3D shape, and thickness tolerances of ± 0.1 mm for instrument panels and door panels with a 3D, two-color design. The skin is PVC free with excellent mechanical properties, excellent appearance, and fit & finish with very sharp radii, resulting in a soft-touch panel. | ||
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Body Interior - Entry 6 |
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Integrally Molded Hidden Airbag Door Chute and Cover |
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| OEM: | General Motors | |
| Model: | Chevy Malibu / Pontiac G6 | |
| Model Year: | 2004 | |
| System Supplier: | Delphi Corporation | |
| Molder / Processor: | Delphi Corporation | |
| Toolmaker: | Pro-Tech | |
| Material Supplier: | GE Advanced Materials | |
| Generic Resin Type: | PC/ABS | |
| Resin Trade Name: | Cycoloy | |
| Grade: | IP1000 | |
| Summary: The chute to direct passenger airbag deployment from a hidden door in a structure-mounted module is molded directly into the main instrument-panel retainer. A pattern of offset molded-in relief, followed by hot-knife trim ensures consistent tear-seam performance without the need of metal reinforcement. The chute is designed with energy-absorbing material to control head-impact loads as well as directing airbag deployment. | ||
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Body Interior - Entry 32 |
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MIC Low-Gloss, Soft-Touch Door-Handle Bezel |
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| OEM: | General Motors | |
| Model: | Chevrolet Trailblazer | |
| Model Year: | 2006 | |
| System Supplier: | MacDonald Industrial Products | |
| Molder / Processor: | MacDonald Industrial Products | |
| Toolmaker: | Mattson | |
| Material Supplier: | Ticona | |
| Generic Resin Type: | POM | |
| Resin Trade Name: | Celcon | |
| Grade: | UV140LG | |
| Summary: This application achieves a molded-in color (MIC), low-gloss, soft-touch appearance without the use of paint. The door handle bezel has a warm, matte finish out of the mold, and also offers high creep modulus, which enables the use of a snap-fit assembly for lower assembly costs (over $1.50 each), reduced parts, and improved long-term performance. | ||
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Body Interior - Entry 33 |
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High-Modulus HVAC Louvers |
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| OEM: | General Motors | |
| Model: | Corvette | |
| Model Year: | 2005 | |
| System Supplier: | Intier | |
| Molder / Processor: | Summit Polymers | |
| Toolmaker: | Summit Polymers | |
| Material Supplier: | Ticona | |
| Generic Resin Type: | LFRT PA | |
| Resin Trade Name: | Celstran | |
| Grade: | PA6GF60 | |
| Summary: This high-modulus heating / ventilation / air conditioning (HVAC) vane provides a "robust feel." The application eliminated the need for metal reinforcement in the louver, saving the cost and mass of a cast-metal alternative. Despite being molded from a 60%-glass-filled long-fiber-reinforced thermoplastic (LFRT) nylon polymer, the material still features a Class-A, molded-in color finish. | ||
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Body Interior - Entry 54 |
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Flip-'n-Fold Load Floor |
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| OEM: | DaimlerChrysler | |
| Model: | Mini-Van | |
| Model Year: | 2006 | |
| System Supplier: | Intier Automotive | |
| Molder / Processor: | Ontegra Brighton | |
| Toolmaker: | Trend Tool | |
| Material Supplier: | Huntsman Polyurethanes | |
| Generic Resin Type: | SRIM | |
| Resin Trade Name: | N/A | |
| Grade: | N/A | |
| Summary: The redesigned load-floor doors enable customer access to a floor storage area in all seat positions. A locking-bar apparatus allows the load floor to provide dual function, so the space can be used for cargo or seat storage. The carpet is molded directly to the structural reaction-injection molding (SRIM) substrate, generating additional cost savings and improving quality. | ||
