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| WINNER |
Powertrain - Entry 28 |
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Water-Jacket Spacer |
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| OEM: | Toyota | |
| Model: | Crown | |
| Model Year: | 2003 | |
| System Supplier: | Aisan Industry Co. | |
| Molder / Processor: | Uchiyama Manufacturing Co. | |
| Toolmaker: | Uchiyama Manufacturing Co. | |
| Material Supplier: | DuPont K.K. | |
| Generic Resin Type: | PPA | |
| Resin Trade Name: | Zytel | |
| Grade: | HTN 51G35HSL | |
| Summary: The water-jacket spacer directs coolant flow to transfer heat away from key areas of the cylinder bore liner, and the improved cooling increases fuel economy and extends engine life. Molded in PPA resin, this is a breakthrough application because it is the first water-jacket spacer designed for open-deck engines. | ||
| Finalist |
Powertrain - Entry 29 |
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Crankshaft Flange |
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| OEM: | Volkswagen | |
| Model: | N/A | |
| Model Year: | 2004 | |
| System Supplier: | Kaco GmbH + Co. KG | |
| Molder / Processor: | Kaco GmbH + Co. KG | |
| Toolmaker: | N/A | |
| Material Supplier: | Ticona GmbH | |
| Generic Resin Type: | PPS | |
| Resin Trade Name: | Fortron | |
| Grade: | 4332L6 | |
| Summary: Three different plastic materials are combined to form this crankshaft flange. The flange integrates the sensor plus multiple wheels for determining the crankshaft's position and speed. The process used to manufacture the part involves a plasma pretreatment of polytetrafluoroethylene (PTFE), overmolded with polyphenylene sulfide (PPS), then plasma pretreatment of the crankshaft flange and overmolding with ethylene acrylic elastomer (AEM). The new crankshaft design provides a 56% weight savings and improved reliability. | ||
| Finalist |
Powertrain - Entry 58 |
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Turbo Intake Manifold |
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| OEM: | DaimlerChrysler | |
| Model: | PT Cruiser Turbo & GT | |
| Model Year: | 2005 | |
| System Supplier: | Siemens Automotive | |
| Molder / Processor: | Siemens Automotive | |
| Toolmaker: | Active Burgess | |
| Material Supplier: | DuPont Automotive | |
| Generic Resin Type: | GF PA | |
| Resin Trade Name: | Zytel | |
| Grade: | EFE7276-BK398 | |
| Summary: The PT Turbo air-intake manifold (AIM) was converted from aluminum to nylon (polyamide (PA)) 6/6, resulting in a $3-million annual part-cost savings. The part also commonized the lower plastic manifold as well as the press-in-place gasket. The plastic design provides a 10-lb weight savings. It is the first plastic manifold for a turbocharger application. An engine NVH and beauty cover was added to reduce NVH by 3 dB. | ||
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Powertrain - Entry 30 |
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Alternator Cooling Cover |
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| OEM: | Ford | |
| Model: | Fusion and Milan | |
| Model Year: | 2006 | |
| System Supplier: | Plastech | |
| Molder / Processor: | Millennium Plastic Technologies | |
| Toolmaker: | N/A | |
| Material Supplier: | Chevron Phillips Chemical Company LP | |
| Generic Resin Type: | 40% GF PPS | |
| Resin Trade Name: | Ryton | |
| Grade: | R-4-200BL | |
| Summary: The integrated cooling-cover design for the Ford Fusion alternator is molded in a 40%-glass-filled polyphenylene sulfide (PPS) material. The cover design reduced development costs by allowing greater versatility in packaging of the alternator, while meeting the 400oF working temperature requirements. Significant engine-development cost savings were realized due to the cover design. | ||
