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Coolant Adapter Manifold / Housing |
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| OEM: | DaimlerChrysler | Model: | World Engine (Dodge® Caliber/Chrysler® Sebring) |
| Model Year: | 2006 | Molder/Processor: | Miniature Precision Components |
| System Supplier: | Miniature Precision Components | Molder Contact: | Brant Lyall |
| System Contact: | Brant Lyall | Molder Phone: | 248-799-8949 x5530 |
| System Phone: | 248-799-8949 x5530 | Material Supplier: | Solvay Advanced Polymers |
| Toolmaker: | Industrial Molds Group | Material Contact: | Kathleen Murtagh-Galea |
| Toolmaker Contact: | Jim Bauscher | Material Phone: | 313-300-5716 |
| Toolmaker Phone: | 815-381-7648 | Generic Resin Type: | PPA Glass Filled |
| OEM Permission: | Yes | Grade: | AS-1933 HS BK324 |
| OEM Engineer: | Mark Thelen/Joe Vargo | Nominator: | Justin Rajewski |
| OEM Title: | Engineer/Designer | Nominator's Company: | DaimlerChrysler |
| OEM Phone: | 248-944-2997/248-576-3195 | Nominator's Address: | CIMS 484-1-17 800 Chrysler Dr. Auburn Hills, MI 48326 |
| Forming Process: | Injection Molding | Nominator's Phone: | 248-944-0982 |
| First Time Process Used? | Yes | Nominator's Email: | jdr69@dcx.com |
| Weight Savings: | The change to plastic saved 49% and 880 grams, of that, the spin weld saved 56 grams, or 6.6% of the total weight. | Cost Savings: | Spin welding the port saved approximately 5% of the total cost, change to plastic and associated elimination of machining saved approx 20% of total cost. |
| Cost Avoidance: | Reduction in labor by not having to install the seal and 3 bolts. Also, only have to load 2 inserts into mold instead of 5. | ||
| Summary: This coolant adapter manifold – using a hermetically spin-welded seal that is more than 3 in. (7.6 cm) in diameter – is manufactured for a high-volume 2006 MY DaimlerChrysler world engine. The spin-seal design reduced mass by 7%. By converting the manifold from aluminum to PPA, all machining for the gasket surfaces, the press-in-place grooves, and the pressed-in hose ports were eliminated, reducing overall costs by 20% and weight 50% vs. the original metal housing. | |||
| Most Innovative Feature: Designed a hermetically sealing spin weld over 3" in diameter using PPA. | |||
| Other Innovative Features: Reduction in weight
and elimination of all machining (gasket surfcaes, press in place
grooves, and pressed in hose ports) vs original aluminum housing. |
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