|
FINALIST |
|||
|
|
|||
|
(click on the picture to see a larger illustration - it opens in a new window, close that window to return here) |
|||
| Description: | Pressure Formed IP Top Pad | Model: | Sebring |
| OEM: | Chrysler LLC | Model Year: | 2006 |
| System Supplier: | Faurecia Interior Systems | Generic Resin Type: | PP 20% talc |
| Molder/Processor: | Pearl | Resin Trade Name: | N/A |
| Toolmaker: | KTX America | Grade: | N/A |
| Material Supplier: | O'Sullivan | Other Innovative Features: | Features dual gloss on a dual cavity tool |
| Most Innovative Feature: | This is the largest component (Top Pad) to use textured mold pressure forming known to date. | Forming Process: | Pressure forming in mold graining |
| Weight Savings: | Approximate weight savings of 45 grams | First Time Process Used? | Yes, First time to produce a Top Pad IP component. |
| Cost Savings: | 35% cost savings | Previous Process: | Replaces spray adhesive system, back foam injection process and PU back foaming processes |
| Cost Avoidance: | Reduced process for foaming | Transferable to Other Vehicles: | Yes it can be translated to other OEM's |
| Benefits to Consumer: | |||
| N/A | |||
| Method Comments: | |||
| New skin material developed with pre-applied adhesive on rolled goods | |||
| Innovations/Improvements: | |||
| Dual gloss master model wrapping material and pressure lamination using preheated substrates | |||
| Safety Improvements: | |||
| Exceeds current safety requirements due to the fact that current material does not need to be scored for deployments and is invisible to the end customer. | |||
| Environmental Comments: | |||
| 100% Environmentally friendly, No polyurethane foam & no spraying of adhesives (0 carbons) and no scoring to the skin material | |||
| Additional Comments: | |||
| This product is a two shot process in which two materials are brought together giving a perfectly formed part with uniform grain through out. There is no stretch or loss of grain as in traditional vacuum forming process and all radii are crisp and clean. | |||
| Summary: | |||
| This top pad is the largest known component to use the in-mold graining pressure forming process. Replacing a 3-step spray-adhesive / injection molding / PUR back foaming process, the product is produced in a 2-shot process that yields crisp radii and uniform grain with no stretch or loss of graining as seen in traditional vacuum forming. As produced, the part is 45 g lighter, 35% less costly, and capital investment was reduced 40% vs. traditional in-mold graining / foam-in-place operations. The finished part does not need to be scored for airbag deployments and is invisible to customers. The 100% olefin family facilitates recycling and eliminates the VOCs associated with PUR foam and adhesive spray. | |||
