FINALIST

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Description: Composite Door Module & Trim System Model: P3 Cascadia
OEM: Freightliner Model Year: 2007
System Supplier: Delphi Interiors and Closures Generic Resin Type: PP
N/A Florida Production Engineering Resin Trade Name: N/A
Toolmaker: UTC Grade: 40% Glass Fiber - PP, PP's
Material Supplier: Adell Plastics Other Innovative Features: Sealed structural trim assembly with a vibration welded map pocket. Simple tooling with no major slides for a complex system. Structural functions such as downstop, lift arm bearing, etc incorporated into a single molded carrier.
Most Innovative Feature: Multifunctional Hardware Carreir with integrated structural, mechanical and class A trim surface with a low cost single polyproylene resin based family of compounds Forming Process: Injection molding, vibration welding
Weight Savings: 2.5 Kg per door First Time Process Used? Vibration welding is used for the first time to integrate a sealed map pocket structure in vehicle door trim. First time design of a cosmetic load bearing multifunctional panel
Cost Savings: $2.00 per part plus $200,000 tool cost savings Previous Process: Sheet steel panel with a structural foam trim panel and add on mechanical components.
Cost Avoidance: About $5.00 for labor savings, additional savings due to 100% automated end of line testing; Other savings due to less material handling, reduced floor space etc. Transferable to Other Vehicles: YEs
 
Benefits to Consumer:
Increased vehicle payload. Improved appearance and tactile feel.
Method Comments:
Molded in color and harmonized with various compounds. Gloss levels matched. Easy flow, low creep and improved physical properties at elevated temperatures.
Innovations/Improvements:
Sequential gating is used to attain structural integrity at load bearing areas and to minimize warpage, pass through coring, vibration weld nesting.
Safety Improvements:
N/A
Environmental Comments:
All plastic parts are the same PP family and totally recyclable.
Additional Comments:
Low cost solution implemented in record timing using predictive engineering tools.
Summary:
This multifunctional hardware carrier and structural trim assembly features integrated structural, mechanical, and Class A trim surfaces and a vibration welded map pocket while saving 2.5 kg of mass per door, $2 cost per part, $200,000 in tooling savings, and $5 USD of labor savings, plus additional savings due to 100% automated end of- line testing. A single family of low-cost, 100% recyclable polypropylene compounds improves appearance and tactile feel.

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All plastic parts are the same PP family and totally recyclable
Low cost solution implemented in record timing using predictive engineering tools


This multifunctional hardware carrier and structural trim assembly features integrated structural, mechanical, and Class A trim surfaces and a vibration welded map pocket while saving 2.5 kg of mass per door, $2 cost per part, $200,000 in tooling savings, and $5 USD of labor savings, plus additional savings due to 100% automated end of- line testing. A single family of low-cost, 100% recyclable polypropylene compounds improves appearance and tactile feel.