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WINNER |
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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: | Electronic Throttle Control Module | Model: | Pacifica |
| OEM: | Chrysler LLC | Model Year: | 2007 |
| System Supplier: | Bosch | Generic Resin Type: | BMC (Thermoset Polyester) |
| Molder/Processor: | Christophery | Resin Trade Name: | Tetradur |
| Toolmaker: | N/A | Grade: | BMC TD 455 |
| Material Supplier: | BMC Inc. | Other Innovative Features: | This throttle unit has the tightest concentricity of any other plastic predecessor to better control air flow at idle. Motor housing, gearbox and gear pins are molded into the unit. Has a snap-on PBT cover feature so there are no fasteners. |
| Most Innovative Feature: | The ETC housing is molded using a Zero-shrink material. With this technology, there was no machining required to maintain bore roundness, reducing tooling modifications and post machining operations. | Forming Process: | Injection molding using a diaphragm gate |
| Weight Savings: | There was a 28% weight savings based on the housing weight difference only. | First Time Process Used? | Yes, this is the first plastic ETC unit. Before electronic control, there was a thermoplastic throttle body, however, this was fender mounted, where this one is engine mounted. |
| Cost Savings: | Production costs are essentially the same. The savings is only from the elimination of the machining step. (actual number not available yet) | Previous Process: | Previous ETC units were produced from machined cast aluminum. |
| Cost Avoidance: | N/A | Transferable to Other Vehicles: | Yes, The design has already been modified to fit the 3.3L, 3.7L, 4.7L, and 8.4L engines. |
| Benefits to Consumer: | |||
| N/A | |||
| Method Comments: | |||
| The BMC TD 455 material was developed with an additive resin to expand as the material cures and shrinks in the tool - giving zero shrink at all thicknesses in the part. | |||
| Innovations/Improvements: | |||
| Tooling required special core pulls and coining because of the complexity and to improve packing and surface finish. Second generation also had a vaccuum draw. | |||
| Safety Improvements: | |||
| Reduce ice freeze-up, preventing potential for throttle blade stick. | |||
| Environmental Comments: | |||
| N/A | |||
| Additional Comments: | |||
| The throttle housing also has a molded in stop feature to zero the blade and handle multiple spring-loaded impacts. A coining feature at the pin location helps improve packing in this area for added strength. | |||
| Summary: | |||
| This is the first plastic ETC housing, which replaces machined cast aluminum at mass savings of 28% and costs savings of 18%, while also reducing warranty costs and potential for ice freeze-up and potential throttle blade stick. A special zero-shrink BMC grade was used and the units tight concentricity better controls air flow at idle. | |||
