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Instrument Panel with RIM Skin |
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| OEM: | Ford | Model: | Lincoln MKX |
| Model Year: | 2007 | Molder/Processor: | Intertec Systems |
| System Supplier: | Intertec Systems | Molder Contact: | Diana Farsakian |
| System Contact: | Diana Farsakian | Molder Phone: | 248.743.6618 |
| System Phone: | 248.743.6618 | Material Supplier: | Intertec Systems and Basell Polyolefins |
| Toolmaker: | EPW | Material Contact: | Diana Farsakian/J. Horal-TPO |
| Toolmaker Contact: | Mike Masserant | Material Phone: | J. Horal-TPO (248)756-3020 |
| Toolmaker Phone: | Generic Resin Type: | PUR, TPO | |
| OEM Permission: | Grade: | TPO Hostacom TRC727N | |
| OEM Engineer: | Nominator: | Jane Horal | |
| OEM Title: | Materials Engineer | Nominator's Company: | Basell Polyolefins |
| OEM Phone: | 313.805.4833 | Nominator's Address: | 2727 Alliance Dr. Lansing, MI 48910 |
| Forming Process: | Reaction Injection Molding (RIM) for the skin; TPO mold-in-color substrate | Nominator's Phone: | (248)756-3020 |
| First Time Process Used? | Yes | Nominator's Email: | jane.horal@basell.com |
| Weight Savings: | N/A | Cost Savings: | Reduced cycle time and tooling resulted in a direct cost savings to Ford for RIM vs. traditional sprayed urethane process at an estimated $15 per vehicle x 42K unit = $630,000 per year, $2,520,000 program life, and $400K in tooling. |
| Cost Avoidance: | Indirect cost savings to Ford was the estimated capital equipment cost savings to Intertec Systems of $1.5M. | ||
| Summary: This instrument panel (IP) skin uses a 2-component, aliphatic polyurethane (PUR) elastomer modified for the RIM molding process in a closed cavity process. This results in reduced cycle time and lower tooling investment. Skin-thickness control, low-temperature ductility, and tear properties of the polyurethane RIM skin are key enablers for integration of the seamless passenger airbag. The estimated savings vs. alternative technologies is $15 USD / vehicle. | |||
| Most Innovative Feature:The innovation being submitted is the use of Reaction Injection Molding (RIM) manufacturing technology in the production of the Lincoln MKX instrument panel skin. | |||
| Other Innovative Features: A two component
aliphatic urethane chemical reaction process in a closed cavity. |
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