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| WINNER |
Process / Assembly / Enabling Technologies - Entry 63 |
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Bonded Hybrid Metal-Plastic Front End Carrier |
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| OEM: | Volkswagen | |
| Model: | Polo A05GP | |
| Model Year: | 2005 | |
| System Supplier: | Simoldes | |
| Molder / Processor: | Simoldes | |
| Toolmaker: | Simoldes | |
| Material Supplier: | Dow Automotive | |
| Generic Resin Type: | GF PP | |
| Resin Trade Name: | Inspire/Betamate | |
| Grade: | DLGF9310.001ZB LESA 74030/74031 | |
| Summary: The stiffness / weight ratio of the world's first bonded front-end carrier is maximized by adhesively bonding a metal reinforcement to an injection-molded thermoplastic-composite component. By bonding the parts together, stress concentrations are reduced on the composite part and the load is spread over the structure, enabling higher stiffness and load-bearing capacity. The metal is bonded to the long-glass-fiber polypropylene (LGF-PP) composite using a special 2-component acrylic adhesive, which has been designed to structurally bonds to low-energy substrates like PP without surface pre-treatment. | ||
| Finalist |
Process / Assembly / Enabling Technologies - Entry 2 |
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Integrally Molded HVAC Seal |
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| OEM: | Ford | |
| Model: | Lincoln | |
| Model Year: | 2006 | |
| System Supplier: | Delphi Thermal and Interior | |
| Molder / Processor: | Carlisle Engineered Products | |
| Toolmaker: | Asis Co., LTD | |
| Material Supplier: | Washington-Penn | |
| Generic Resin Type: | 20% TF PP | |
| Resin Trade Name: | N/A | |
| Grade: | N/A | |
| Summary: An airtight seal for HVAC case joints has been created through the use of lateral compression of the split tongue, thus eliminating air leakage as cases separate under load, temperature, or pressure conditions. This robust sealing system enables the use of snap features to assemble the cases, since an airtight seal is maintained even with the over-travel clearance required to engage the snaps. The snap design also includes a unique case-to-case alignment feature. | ||
| Finalist |
Process / Assembly / Enabling Technologies - Entry 7 |
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Partial Mold-Behind Integrated Trim Panel |
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| OEM: | General Motors | |
| Model: | Chevrolet Impala | |
| Model Year: | 2006 | |
| System Supplier: | Johnson Controls Inc. | |
| Molder / Processor: | Johnson Controls Inc. | |
| Toolmaker: | Viking Tool | |
| Material Supplier: | Basell Polyolefins | |
| Generic Resin Type: | PP | |
| Resin Trade Name: | ProFax | |
| Grade: | SD242 | |
| Summary: This new process creates a one-piece trim panel that integrates multiple textiles in a single machine cycle. This replaces a multi-piece construction and heat-staking operations traditionally used. Tooling innovations include end-of-arm robotics, a fabric retention and placement mechanism, and a material interface/finishing ditch. The new process provides improved craftsmanship and product characteristics (BSR, long-term durability), and is environmentally friendly, reducing material usage, eliminating glue, and producing less waste. | ||
| Finalist |
Process / Assembly / Enabling Technologies - Entry 46 |
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Thick Sheet Thermoformed Exterior Trim |
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| OEM: | DaimlerChrysler / General Motors | |
| Model: | Jeep Renegade / Buick Lucerne | |
| Model Year: | 2005 | |
| System Supplier: | Flex-N-Gate/Durakon Industries | |
| Molder / Processor: | Durakon Industries | |
| Toolmaker: | Tooling Technologies / Portage Casting | |
| Material Supplier: | EquistarChemical / Solvay Engineering Polymers / Soliant | |
| Generic Resin Type: | TPO | |
| Resin Trade Name: | N/A | |
| Grade: | PD907/E3000 | |
| Summary: This is the first mass production of a “thick-sheet” paint film with Class A for exterior-trim panels. The material and process consistently meets the DOI and gloss requirements of painted parts, while providing 2x greater durability than paint. The component attaches to the vehicle with attachment features that are similar to those used with the previous injection-molded part. Weight and cost savings of 30% were achieved vs. injection-molded plastic appliqués. | ||
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Process / Assembly / Enabling Technologies - Entry 1 |
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Balanced As-Molded HVAC Fan |
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| OEM: | General Motors | |
| Model: | W-Car | |
| Model Year: | 2003 | |
| System Supplier: | Delphi Thermal & Interior Division | |
| Molder / Processor: | Delphi Thermal & Interior Division | |
| Toolmaker: | Delphi Thermal & Interior Division | |
| Material Supplier: | Basell Polyolefins | |
| Generic Resin Type: | PP | |
| Resin Trade Name: | ProFax | |
| Grade: | PDC1273 | |
| Summary: The injection-molded heating / ventilation / air conditioning (HVAC) blower fan was engineered with reduced molding variability. This eliminated post-mold balancing of the motor and fan. The fan's rim design also reduces run-out variation and improves the burst strength of the fan blades. | ||
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Process / Assembly / Enabling Technologies - Entry 3 |
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Headliner with Self-Reinforced Sunroof Opening |
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| OEM: | Nissan | |
| Model: | Maxima | |
| Model Year: | 2005 | |
| System Supplier: | Lear Corporation | |
| Molder / Processor: | Lear Corporation | |
| Toolmaker: | ||
| Material Supplier: | Azdel, Inc. | |
| Generic Resin Type: | LD-GMT | |
| Resin Trade Name: | Azdel Superlite | |
| Grade: | SL551000.101 | |
| Summary: A secondary edge folding of the headliner cover is used to simultaneously heat stake the headliner substrate to itself, thus strengthening and improving the rigidity of the sunroof daylight opening (DLO). A low-density glass-mat thermoplastic (GMT) composite provides the thermoplastic substrate that makes this operation possible. This process eliminates the need for an inner reinforcing garnish ring (providing a vehicle savings of $1 / part) and provides a cleaner appearance. | ||
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Process / Assembly / Enabling Technologies - Entry 4 |
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TPV Upper Reveal Molding |
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| OEM: | General Motors | |
| Model: | Buick Lucerne | |
| Model Year: | 2006 | |
| System Supplier: | Decoma International | |
| Molder / Processor: | Co-Ex-Tec | |
| Toolmaker: | Micro Mold | |
| Material Supplier: | ExxonMobil | |
| Generic Resin Type: | TPV | |
| Resin Trade Name: | N/A | |
| Grade: | N/A | |
| Summary: Heat-forming of multi-layer thermoplastic vulcanizate (TPV) extrusions allows the elimination of metal stampings and simplifies roll-forms typically used in a multi-piece assembly. Integrated appearance is achieved through elimination of plastic / steel joint. By eliminating the steel stampings, significant mass and cost savings are achieved. A co-extruded slip coat also eliminates secondary assembly operations. | ||
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Process / Assembly / Enabling Technologies - Entry 5 |
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Sonic-Weld HVAC Dual Lock Valance-Panel Attachment |
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| OEM: | Ford | |
| Model: | Freestyle / Montego / 500 | |
| Model Year: | 2005 | |
| System Supplier: | Visteon Corporation | |
| Molder / Processor: | Toledo Mold and Die / Sarnamotive Blue Water Inc. | |
| Toolmaker: | Derby Manufacturing | |
| Material Supplier: | 3M | |
| Generic Resin Type: | PP | |
| Resin Trade Name: | N/A | |
| Grade: | N/A | |
| Summary: This is the first application of sonic welding to attach Dual Lock low-profile reclosable fasteners to valance panels. The process replaced the previous method of gluing the fasteners onto the PP substrate material, which required use of an adhesion promoter and a secondary cure cycle. An ultrasonic horn was developed and the material and process were refined so as not to damage the fastener stems during welding. | ||
