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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: | Transmission Thermal Valve Assembly | Model: | Sentra |
| OEM: | Nissan | Model Year: | 2006 |
| System Supplier: | Cooper-Standard Automotive | Generic Resin Type: | PPA |
| Molder/Processor: | Calico | Resin Trade Name: | Zytel |
| Toolmaker: | Lutman Precision Mold | Grade: | HTN 51G35 HSLR |
| Material Supplier: | DuPont Automotive | Other Innovative Features: | An overmolded bracket accomplishes two functions, joint sealing and vehicle mounting interface. |
| Most Innovative Feature: | First transmission bypass valve with plastic poppet with patented integrated overmolded metal to plastic joint cuts weight and enables parts integration. | Forming Process: | Three unique overmolded processes to join rubber and plastic to metal. Eliminates costly fittings and components, metal crimp, and welding processes. Reducing the number of leak paths, and post plating processes. Improving corrosion resistance and reducing weight. |
| Weight Savings: | 50% savings | First Time Process Used? | Three Firsts: (1) Cooper-Standard designed this assembly to integrate multiple components into one unit utilizing patented plastic to aluminum overmolded joint process; (2) application overmolded rubber hose joint with integrated mounting function; (3) plastic to aluminum overmolded bracket on TBV assembly. |
| Cost Savings: | 30% savings | Previous Process: | Traditional designs relied on metallic components, welding, crimping, plating, clamp assembly and many process steps. |
| Cost Avoidance: | Localized in North America resulting in Logistic Savings. For example: OEM inbound freight savings by eliminating sea freight from Asia, customs and import duties, less packaging waste, and reduced supply chain risks due to localization in North America. Fuel Savings | Transferable to Other Vehicles: | Yes, Nissan investigating future vehicle applications worldwide. |
| Benefits to Consumer: | |||
| Light weight improves fuel economy and lowers Hydrocarbon and C02 emissions. | |||
| Method Comments: | |||
| Not Applicable | |||
| Innovations/Improvements: | |||
| Not Applicable | |||
| Safety Improvements: | |||
| Reduced chance for leak due to improved joint technology. | |||
| Environmental Comments: | |||
| Light weight improves fuel economy and lowers Hydrocarbon and C02 emissions. | |||
| Additional Comments: | |||
| Improves corrosion resistance due to eliminating plating, metal clamps, crimping and welding processes. | |||
| Summary: | |||
| This is the first transmission by-pass valve with plastic poppet utilizing a patented, overmolded metal-to-plastic joint, which eliminates costly fittings and components, metal crimping, and welding processes. The application produced a 50% weight and 30% cost savings, while improving performance and reducing leaks. | |||
