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FINALIST |
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(click on the picture to see a larger illustration - it opens in a new window, close that window to return here) |
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| Description: | Integrated Tailgate Step | Model: | Super Duty Truck |
| OEM: | Ford Motor Company | Model Year: | 2008 |
| System Supplier: | Multimatic | Generic Resin Type: | GF PP |
| Molder/Processor: | Plastcoat | Resin Trade Name: | Polyfort |
| Toolmaker: | N/A | Grade: | FPP 1239H |
| Material Supplier: | A.Schulman, Inc. | Other Innovative Features: | Based on customer interactions, Ford engineering translated the need to enter the box into a useable design.Nine separate assemblies make-up the step system. Each performs specific functionalities combing metal and several plastics to achieve it's unique features such as; flip step is partially sprung open, anti-slip step, anti-slip tailgate liner. |
| Most Innovative Feature: | Industry first integrated tailgate step system with 7 patents awarded and 3 more pending. Innovative, intuitive design allows for quick deployment,safe operation with grab handle design, for easier box ingress and egress. Multi-functional center molding of Polyfort FPP 1239H provides attractive,durable, weatherable trim, strength through 2 piece welded design, integral release function, clip, pivot, and T-stops. | Forming Process: | The major plastics component, the center molding, is injection molded using Polyfort FPP 1239H, a 30% glass reinforced polypropylene. The roller carriers are overmolded with Delrin 100 for smooth, durable action. The tailgate liner is a vacuum formed dual extruded HDPE liner with a specially formulated with anti-slip coating. |
| Weight Savings: | N/A | First Time Process Used? | No |
| Cost Savings: | N/A | Previous Process: | As an industry first, this step system design is truly unique and a breakthrough design in it's seeming simplicity of use and function with underlying novel, patented, technologies throughout it many components. |
| Cost Avoidance: | N/A | Transferable to Other Vehicles: | This concept can be extended to other vehicles. |
| Benefits to Consumer: | |||
| This application represents the translation of an unmet customer need; easy, safe, entry into the pick-up box, into a highly technical, unique design representing the first integrated tailgate step in the industry on the 2008 Ford Super Duty trucks. Based on dealer feedback and customer response this feature delivers significant value to the truck customer. | |||
| Method Comments: | |||
| The Polyfort 30% GR polypropylene uniquely provides mechanical stength, weldability, molded in color matched exterior weatherable appearance, grip, and the durability required to meet Ford's Super Duty mantra. | |||
| Innovations/Improvements: | |||
| In the step tailgate construction common stampings with unique trim die and retractable punches were utilized. | |||
| Safety Improvements: | |||
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The step system allows a truck user safe, consistent and reliable
ingress and egress avoiding other approaches that owners might
employ to enter their truck boxes. |
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| Environmental Comments: | |||
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Since the step system is built tough, long lasting, and it always
stays with the vehicle it avoids wasting materials for temporary
entry and potential environmental clutter. |
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| Additional Comments: | |||
| One of the key features that makes this
entry so innovative lies in the way the original customer need was
met. On the surface the customer need is quite simple, easy entry
and exit from a truck box. The Ford Super Duty solution is equally
simple in it's function and operation belying the complexity,
originality, and elegance of the Ford engineering teams solution.
With sound, creative engineering, form and function combine to
generate smiles on customer faces and business game changers. |
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| Summary: | |||
| Industry’s first integrated tailgate step system features 9 separate assemblies of plastic and metal that provide a simple yet technical solution to an unmet customer need: for easy, safe entry into a pickup box. The main component’s GR-PP material provides mechanical strength, weldability, molded-in color, long-term weatherability, aesthetics, slip resistance, and durability to meet Ford’s specs. The product has been awarded 7 patents, with 3 additional patents pending. | |||
