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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 Transmission Baffle/Seal Lip | Model: | Chevrolet Malibu; GM Daewoo Tosca; Buick LaCrosse China |
| OEM: | General Motors | Model Year: | 2008 |
| System Supplier: | Chunil Engineering | Generic Resin Type: | TPC/ET -thermoplastic elastomer |
| Molder/Processor: | Chunil Engineering | Resin Trade Name: | Hytrel |
| Toolmaker: | Chunil Engineering | Grade: | N/A |
| Material Supplier: | DuPont Automotive | Other Innovative Features: | Use of thermoplastic elastomer enables unique, GM patented design for a single attachment ((current metal systems have appx. 10 attachment points that require rivets or screws.)) |
| Most Innovative Feature: | First integrated transmission baffle/lip seal system with single material - GM patent pending - eliminates oil aeration for improved clutch durability to 200,000 miles; 50% increase in oil life; 45% improvement in pump performance; smoother shift. | Forming Process: | Injection Molding - one piece with integrated seals using hot runners |
| Weight Savings: | 7X decrease in weight - 2 integrated baffle/seal lips per vehicle | First Time Process Used? | Yes |
| Cost Savings: | 20% direct, but initial design abandoned in favor of this option | Previous Process: | Previous Metal stamping or plastic carrier with rubber bead. |
| Cost Avoidance: | Protection against failure (even at a 1% rate) saves 36 million. Additional $1 per part due to elimination of secondary molding operations; significantly reduced scrap rate; improved cycle times | Transferable to Other Vehicles: | Yes and is - another OEM is considering adoption for new high-volume transmission program; generation 2 in development with GM |
| Benefits to Consumer: | |||
| Improved shift for better ride and drive; improved environment (transmission fluid sealed for life of transmission) and improved horsepower due to better pump efficiency | |||
| Method Comments: | |||
| Unique heat stabilizer package; added resistance to automatic transmission fluid. | |||
| Innovations/Improvements: | |||
| More a benefit in tooling - Natural elasticity of material allows part stripping without tear thereby eliminating secondary operations. Hot runner valve gate direct injection | |||
| Safety Improvements: | |||
| N/A | |||
| Environmental Comments: | |||
| Improved recyclability and reduced scrap; no automatic transmission fluid replacement; Energy saving owing to weight reduction | |||
| Additional Comments: | |||
| 2-year development cycle working in a global environment in an industry where averages run 5-7 years | |||
| Summary: | |||
| This is the first-ever single-material design for an integrated transmission baffle/lip seal. The GM patent-pending design eliminates oil aeration for improved clutch durability to 200,000 miles, provides 50% increase in oil life, improves pump performance 45%, and offers easier assembly and provides smoother shift performance. | |||
