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Gas-Assist Injection Molded Coolant Tube |
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| OEM: | Ford | Model: | F250 |
| Model Year: | 2007 | Molder/Processor: | Illinois Valley Plastics |
| System Supplier: | International | Molder Contact: | Jim Mechawski |
| System Contact: | Steve Bielaga | Molder Phone: | (847) 269-1830 |
| System Phone: | (708) 865-4037 | Material Supplier: | Chevron Phillips |
| Toolmaker: | Gain Technology | Material Contact: | Sandra McClelland |
| Toolmaker Contact: | Jim Byrd | Material Phone: | 586-264-0063 |
| Toolmaker Phone: | (586) 532-5400 | Generic Resin Type: | PPS |
| OEM Permission: | Yes | Grade: | R-4-220 BL |
| OEM Engineer: | N/A | Nominator: | Sandra McClelland |
| OEM Title: | N/A | Nominator's Company: | Chevron Phillips |
| OEM Phone: | N/A | Nominator's Address: | 37616 Dartmouth Drive Sterling Heights, MI 48310 |
| Forming Process: | Nitrogen Gas Assist Injection Molding | Nominator's Phone: | 586-292-1794 |
| First Time Process Used? | Yes | Nominator's Email: | mccles@cpchem.com |
| Weight Savings: | 48% | Cost Savings: | Cost savings of 20% over comparable metal tubing. |
| Cost Avoidance: | N/A | ||
| Summary: Metal tubes cannot achieve the bend radii available using the injection molding process and ancilliary features and mounts become available with little effort rather than needing to create a stamping and brazing it onto the metal tube in the proper location and orientation. This is the first plastic coolant tube of complex geometry produced for ‘07 MY Ford F250 pickup engine to withstand longlife coolant and high engine temperatures. It was only made possible by gas-assist injection molding of PPS resin. The resulting part was only half the mass and 20% lower in cost than the conventional metal tubes it replaced. | |||
| Most Innovative Feature: This is the first PPS coolant tube produced using gas assist technology to allow a complex geometry and to withstand longlife coolant and high engine temperatures. | |||
| Other Innovative Features: The tube cannot be
produced with standard injection molding and extruded tubes would not
withstand the application requirements. |
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