· They also realize that the automotive design and ... ments The snap-together design...

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November 9, 2011

Welcome to the 41st-annual SPE Automotive Innovation Awards Gala, sponsored by the Automotive Division of the Society of Plastics Engineers. I am honored to chair this year’s program, the world’s oldest and largest recognition event in the automotive and plastics industries. My Automotive Div. colleagues and I are excited to offer this tribute to the latest innovation in plastics and composites in ground transportation.

Innovation generally takes several years to manifest in a commercial application. If we reflect on what was happening in our industry two-to-three years ago or about the time these innovations were being studied, it is truly amazing that the industry was able to keep the innovation engine running. This year we put the spotlight on those companies that continued to invest in innovation during an extremely difficult time in our industry – innovation that allowed them to create products that consumers need and want despite the strong industry headwinds that existed circa 2008 and 2009.

This year’s theme is Passion to Innovate. Passion can be described as intense or overpowering emotion or, better yet, intense enthusiasm for a subject or activity. The people attending and being recognized at tonight’s event are passion-ate about innovation and the success of their respective companies. They also realize that the automotive design and engineering bar will continue to be raised, demanding new solutions to address vehicle lightweighting, cost reduction, design, and other performance targets. We at the Society of Plastics Engineers eagerly participate in and support those efforts through our annual technical programs, educational activities, and this recognition event.

Tonight’s program will recognize accomplishments in specific vehicle categories and highlight those select individuals and teams with awards in the following areas:

Before we begin tonight’s program, I would like to thank the many volunteers, sponsors and judges who make this event possible. It is their dedication and commitment – their passion – for innovation that enable the SPE Automotive Division to recognize the industry’s most innovative use of polymeric materials in automotive applications.

Welcome to the 41st-annual SPE Automotive Innovation Awards Gala. Thank you for joining us and we hope you enjoy the event.

Jeffrey HelmsJeffrey Helms’10-’11 SPE Automotive Innovation Awards Program ChairTicona Engineering Polymers

• Body Exterior• Body Interior• Chassis & Hardware• Lifetime Achievement Award• Materials• Environmental• Vehicle Engineering Team Award

• Safety• Hall of Fame• Past-Chair Award (SPE Automotive Division)• Process, Assembly & Enabling Technologies• Powertrain, and• The Grand Award

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Mike Brady ReinforcedPlasticsmagazine

Pam BradyReinforcedPlasticsmagazine

Dale BrosiusHigh-PerformanceComposites&CompositesTechnologymagazines

Alexander BuechlerPolymotivemagazine

Suzanne ColeMillerColeLLC

Subi DindaOaklandUniversity

Bob EllerRobertEller&Associates

John FillionChryslerLLC(retired)&EngineeringSocietyofDetroit

Ryan GehmAutomotiveEngineeringmagazine/SAEInternational

Mike LeGaultHigh-PerformanceComposites&CompositesTechnologymagazines

Josh MaddenMoldReleaseProducts

Peggy MalnatiCompositesTechnologymagazine&Omnexus.com

Rhoda MielPlasticsNewsmagazine&PlasticsinLightweight&ElectricalVehiclesConference

Thomas MooreChryslerLLC(retired)

Allan MurrayAlliedCompositeTechnologiesLLC,SPEEmeritus

Matthew NaitovePlasticsTechnologymagazine&PLASPECGlobalPlasticsSelector

Irv PostonGeneralMotorsCorp.(retired)

Ron PriceGlobalPolymerSolutions

Nippani RaoRao&Associates

Tom RussellAlliedCompositeTechnologiesLLC

Doug SmockPlasticsToday.com

Chris TheodoreFordMotorCo./TheodoreAssociatesLLC

Mike TolinskiPlasticsEngineeringmagazine/SPE

William WhiteLawrenceTechnologicalUniversity

Drew WinterWardsAuto.com

Conrad ZumhagenTheZumhagenCompanyLLC

5:00-6:30 pm receptIon / prevIew of nomInated parts & vehIcle dIsplays_____________________________________________________________

6:30 pm seatInG BeGIns_____________________________________________________________

6:45-7:00 pm welcome / dInnerJeff Helms, Ticona Engineering Polymers

and 2011 SPE Automotive Innovation Awards Program Chair

Teri Chouinard, Intuit Group

Maria Ciliberti, Ticona Engineering Polymers_____________________________________________________________

7:00-9:00 pm Gala proGramBody ExteriorTomPickett,GeneralMotorsCo.

Body InteriorYvonneBankowski,FordMotorCo.

Chassis & HardwareScottKlingler,TiconaEngineeringPolymers

Lifetime Achievement AwardFredDeans,AlliedCompositeTechnologiesLLC

MaterialsNormKakarala,IntevaProducts

EnvironmentalMonicaProkopyshen,ChryslerLLC(retired)

Vehicle Engineering Team AwardAnthonyGasbarro,MarubeniAmericaCorp.

SafetySuzanneCole,MillerColeLLC

Hall of FameNippaniRao,Rao&Associates

Past Chair AwardAnthonyGasbarro,MarubeniAmericaCorp.

Process, Assembly & Enabling TechnologiesSureshShah,DelphiCorp.

PowertrainJakeWelland,Hyundai-KiaAmericaTechnicalCenter

Grand AwardJeffHelms,TiconaEngineeringPolymers

_____________________________________________________________

9:00-11:00 pm afterGlow receptIonEveryone Invited to Attend

schedUle of events

Blue ribbon Judges

Special thanks to our student usher sponsor, Ticona and our student usher organizers, Jim Keeler and Jackie Rehkopf.

Welcome to the

medIa / assocIatIon sponsors

Gala & afterGlow sponsor

sIlver sponsor

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™

Bronze sponsorsadvertIsInG only sponsors

Welcome to the

Gold sponsors

medIa / assocIatIon sponsors

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Bronze sponsors

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2 0 1 1 s p e a U t o m o t I v e I n n o v a t I o n a w a r d s c o m p e t I t I o n & G a l a

Spoiler with Integrated Antenna & AmplifierGeneral Motors Co.

2011 MY Chevrolet® Camaro® convertible sports car

System Supplier: ABC Group - Exterior Systems Material Processor: ABC Group - Exterior SystemsMaterial Supplier: Styron LLC Resin / Process: Pulse® 2000 EZ PC/ABS / Blow moldingTooling Supplier: ABC Group – Supreme Tooling

This is the first-ever integrated amplifier and antenna in a blow-molded spoiler. An innovative method was used to incorporate the antenna into and locate the amplifier in the spoiler. Not only were rear-vehicle aesthetics improved, but a 10% weight savings and 66% indirect cost savings were achieved.

Mold-in-Color Ford OvalFord Motor Co.

2012 MY Ford® F250® Superduty pickup

System Supplier: Tribar Manufacturing LLCMaterial Processor: Tribar Manufacturing LLCMaterial Supplier: Evonik Industries / SABIC Innovative Plastics Resin: PMMA & Plating Grade ABSTooling Supplier: Granby Tool Co.

The unique MIC design provides the appearance of a paint-over-aluminum badge without use of paint for significant cost savings and quality improve-ments The snap-together design significantly reduces cost and eliminates paint-adhesion issues with aluminum and has improved performance for stonepecking and denting during assembly, shipping, and customer use. Although weight savings is negligible, there is significant quality and environ-mental improvement (through elimination of paint), resulting in a direct cost savings of 35%.

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Fender Vent Mold-in-Color MultilayersFord Motor Co.

2012 MY Ford® F250®, F350®, F450®, F550® pickups

System Supplier: Lupini Targhe S.p.A.Material Processor: Gamma MoldMaterial Supplier: BASF Corp. Resin: Luran ASA & Chromed ABS Tooling Supplier: Gamma Mold

This injection-molded ASA and chromed ABS design offered black lettering inside a chrome bezel while avoiding costly paint-over-chrome and subse-quent delamination during the life of the vehicle. It is the first MIC exterior side fender-vent application with interchangeable / multi-model lettering. It reduced weight 10% and direct costs 20% while also lowering assembly time.

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Structural ASA Aero SpoilerFord Motor Co.

2012 MY Ford® Edge® & Lincoln® MKT CUVs

System Supplier: ABC GroupMaterial Processor: Delta ToolMaterial Supplier: SABIC Innovative Plastics Resin / Process: Geloy® XP4034 ASA+PC / Gas-counter-pressure injection moldingTooling Supplier: Delta Tool

A patented chemical foaming agent combined w/ASA in a non-traditional injection molding process was used to mold this aero spoiler, which reduces weight 1.5 lb / vehicle (for better fuel economy) and better meets customer requirements. The design allowed for parts integration while maintaining a Class A surface appearance and saving $5.6MM USD direct costs and an estimated $200,000 USD of indirect costs due to reduced complexity vs. the previous process.

Ram Box Assembly with LidChrysler Group LLC

2012 MY Dodge® Ram® pickup

System Supplier: Penda Corp.Material Processor: Penda Corp. (lid), Evco Plastics (bin) River Bend Industries (end caps) Material Supplier: Asahi Kasei Plastics North America Inc. Resin / Process: Thermylene® P8-40FG-4611 (box), P6-15FG-0741 (lid); P6-15FG-0754 (end caps) PP / Twin-sheet thermoformingTooling Supplier: Cavalier Tool & Mfg. Ltd. (injection-molded bin); Tooling Technology LLC (thermoformed lid)

Twin-sheet thermoforming replaces blow molding to create the structure and ribbing of this tough storage box with lid. The result is a more uniform, more dimensionally accurate part whose length was increased from 5 ft 7 in. to 6 ft 4 in., requiring greater emphasis on the “heavy-duty” nature of the structure’s design and materials of construction. A special new grade of GR-PP eliminated the need to upgrade to heavier and more costly PA 6/6, avoiding a 9% weight and 20% cost increase.

B o d y e x t e r I o r

Sealing Stud for Rear Lamp & Appliqué AttachmentsGeneral Motors Co.

2012 MY Chevrolet® E10 pickup

System Supplier: ATF Inc. Material Processor: Not StatedMaterial Supplier: Nylok Corp. Resin: Not StatedTooling Supplier: Not Stated

This application uses a pre-applied sealant on a cold-formed collar stud for rear lamp and appliqué attachments. This is the first application of the sealant to studs for lamps and exterior applications, saving 50% of the weight and 50-60% of the direct cost of previous systems. An additional 60% indirect savings due to cost avoidance was also achieved.

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Second-Row Vanity Mirror & Dome Lamp with Dual LEDFord Motor Co.

2013 MY Lincoln® Town Car® livery

System Supplier: Daimay NA Automotive, Inc. Material Processor: Not StatedMaterial Supplier: Not StatedResin: PC/ABSTooling Supplier: Not Stated

This second-row vanity and dome lamp combo shares a single LED circuit board to serve both vanity and courtesy/reading light functions. Additional features include a light ramp-up intensity feature to provide a luxury feel for Lincoln customers. Molded-in-hooks & snaps on the back of the vanity bezel helped eliminate 4 J-clips, 4 high-retention clips, 4 screws & screw caps, plus labor during vehicle assembly. The resulting system saves 2.02 lb / vehicle vs. previous systems and saved $4 USD/unit direct and $8 USD/vehicle indirect costs vs. separately packaged units.

Seat-Controls Plastic-Module BracketFord Motor Co.

2012 MY Ford® Escape® SUV & Kuga® CUV

System Supplier: Magna Seating LVSS Material Processor: Genesis Material Supplier: BASF Corp. Resin / Process: Ultramid® A3WG6 PA 6/6 30% GF / Injection moldingTooling Supplier: ETCS Inc.

This plastic module bracket for seat controls replaced a steel stamping manufactured in progressive dies with an injection-molded 30% glass-reinforced PA 6/6 material. The approach saves 805 g of weight per vehicle vs. the previous design. Further, it reduces parts from 2 to 1 and increases design frequency from 30 Hz to 61 Hz, eliminat-ing potential NVH issues via a tripod mounting approach with honeycomb construction. It also eliminated $260,000 USD in tooling costs and piece-costs were reduced $0.15/set.

Overmold-Cushion SuspensionFord Motor Co. 2012 MY Ford® Escape® SUV & Kuga® CUV

Group LLC 2012 MY Dodge® Ram® pickup

System Supplier: Flex-O-Lators Div. of Leggett & Platt Inc. Material Processor: Flex-O- Lators Div. of Leggett & Platt Inc. Material Supplier: Washington Penn Resin / Process: PPC5UF0 PP / Injection moldingTooling Supplier: Advanced Mold Engineering Inc.

The injection-molded PP design reduces part count from 5 to 1 / seat, piece cost $0.56 USD per seat, tooling costs $288,000 USD, and per-vehicle mass by 1.93 kg vs. the previous design. The single-piece design provides wire harness routing and retention, seat-cushion and back-trim retention, and climate-control system retention – functionality that previously required 5 parts to achieve. Now there are 5 fewer parts to manage, control, and install and fewer opportunities for potential failure modes.

Low-Gloss, Molded-in-Color Steering-Column CoverBMW AG

2011 MY BMW® 5 Series mid-size luxury sedan

System Supplier: Leopold Kostal GmbH & Co. KG Material Processor: Leopold Kostal GmbH & Co. KG Material Supplier: SABIC Innovative Plastics Resin / Process: Cycolac® DL100LG ABS/PC / Injection moldingTooling Supplier: Not Stated

Use of a new lower gloss, molded-in-color ABS/PC blend eliminates the need for painted ABS/PC blends and provides improved thermal performance vs. straight ABS and PP. The part also provides improved dimensional stability vs. PP. The application saves $1-3 USD/part depending on part size due to elimination of paint and associated scrap.

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Molded-in-Color Air-Register BezelFord Motor Co.

2011 MY Ford® Escape® SUV & Kuga® CUV

System Supplier: TRW Engineered Fasteners & Components Material Processor: Fisher TechMaterial Supplier: Samsung Chemical Resin / Process: WP-1098 PC/ABS / MultipleTooling Supplier: Fisher Tech

The unpainted, low-gloss, PC/ABS Class A surface on these air-register bezels was achieved using injection molding / steam-mold technology and a new material with low gloss and UV resistance. The design also featured a unique method to interface with the chrome-plated ring. The innovation represents an indirect cost save of $1.80 per affected vehicle.

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TPE “Coating” for Center Finish PanelHyundai-Kia Automotive Group

2011 MY Hyundai® Veloster® CUV

System Supplier: Dongkook Corp.Material Processor: Hankook Mold Corp. Material Supplier: Kriburg GmbH & Co. KGResin: TPE HTP8830 / 98Tooling Supplier: Hankook Mold Corp.

Thanks to a sequential injection molding operation on a shuttle press, this center console is coated with a soft-touch TPE, eliminating the need to paint or spray on a coating. This results in a 20% cost reduction and a cycle-time reduction from 2 hr to 2 min.

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Composite Underbody ShieldsGeneral Motors Co.

2012 MY Chevrolet® Volt® extended range EV

System Supplier: Grupo Antolin-Irausa, S.A.Material Processor: Grupo Antolin-Irausa, S.A.Material Supplier: Quadrant Plastic Composites Resin / Process: SymaLITE® LWRT PP+GF / Compression moldingTooling Supplier: Not Stated

These ultra-lightweight composite underbody shields are used to improve aerdynamics for lower fuel consumption and to protect the vehicle’s under-carriage components from stone impacts. The impact behavior is ductile so during a major impact the hole/damage will stay local and cracks will not propogate for better damage tolerance. Low-pressure compression molding is used to form all parts in a single tool; waterjet cutting is used to cut them apart. There was a 15-20% weight savings vs. injection molded plastics.

c h a s s I s / h a r d w a r e

Below Belt Glass BracketFord Motor Co.

2011 MY Ford® Focus® compact car (globally)

System Supplier: Brose Fahrzeugteile GmbH & Co. KGMaterial Processor: Erwin Quarter, Inc.Material Supplier: RheTech, Inc.Resin: PP T20T100 PP / EPDMTooling Supplier: Camoplast Inc.

This multi-shot execution of a below-belt weatherstrip eliminates seal-unzip-ping failure mode. It is an industry-first use of a multi-shot/multi-function bracket that is overmolded to accommodate the glass-run sealing section without need for additional retention clips or u-channel welding/hemming. As such, the PP/EPDM provides robust impact resistance and holding force even after heat aging and china dust exposure, reducing costs 60% vs. the previous method and providing the automaker a $900,000 USD direct and $400,000 USD indirect savings annually.

Outer Belt Weatherstrip Hidden Fastener RetentionFord Motor Co.

2011 MY Ford® All Focus® compact cars (globally)

System Supplier: Henniges Automotive Material Processor: MANUFACTURAS MAHER II, S.L .Material Supplier: BASF Corp. Resin / Process: Ultramid® PA 6/6 / Injection moldingTooling Supplier: Camoplast Inc.

The outer belt weatherstrip eliminates a threaded steel fastener and utilizes a plastic clip retainer. This is industry’s first injection-molded plastic output pinion, which ensures functionality for 6-way locating with just 1 clip. Tough PA 6/6 provides robustness for impact resistance and holding force even after heat aging and high-pressure car washing. The application led to a 70% weight reduction, direct cost savings of $850,000 USD annually and an indirect savings of $450,000 USD each year.

Plastic Racheting-Stud Insert General Motors Co.

2012 MY Chevrolet® Camaro® sports car

System Supplier: ITW Super Products Material Processor: ITW Shanghai Material Supplier: Mitsubishi Engineering Plastics Resin / Process: Lupital® F20-03 POM / Injection moldingTooling Supplier: Donglei Shanghai

This all-plastic, self-centering ratcheting insert replaces metal nuts and allows for a much quicker load / hold (vs. traditional nut / bolt). The POM insert also acts as an isolator to protect the assembly from corrosion, paint chipping, and noise while achieving over 100 lb in pull-force retention. Weight is also reduced 50% and assembly time and warranty costs are reduced.

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B-Pillar AppliquéFord Motor Co.

2011 MY Ford® Focus® compact car

System Supplier: Windsor Mold GroupMaterial Processor: Windsor Mold GroupMaterial Supplier: Evonik Industries Resin: Acyrlite® ABS with PMMA overmoldTooling Supplier: Windsor Mold Group

This is a dual-shot (ABS over PMMA), injection-molded decorative pillar appliqué provides excellent aesthetics and electrical functionality for the vehicle’s keyless entry system. It also provides glass guidance, replacing a steel u-channel. Filling analysis was critical to the success of this design to prevent cracking and over-stressed parts in joints and corners. The result is a 46% weight savings, a $1.4MM USD direct cost savings, and an additional $800,000 USD indirect cost savings.

Power-Window Motor Output Gear & ShaftFord Motor Co.

2011 MY Ford® All Focus® compact cars (globally)

System Supplier: Brose Fahrzeugteile GmbH & Co. KGMaterial Processor: Mitsuba Corp. Material Supplier: DuPont AutomotiveResin / Process: Hytrel® TPC-ET polyester / Injection moldingTooling Supplier: Camoplast Inc.

This power-window motor changed from a steel output pinion to a new injection-molded polyester one for a quieter/lighter motor to meet customer targets while still complying with window velocities. It is industry’s first plastic output pinion that ensures functionality. Additionally, the design allows for regulator plug-‘n-play capability into the power drum for better motion control. Packaging of the involute onto the spline gear to the accommodat-ing drum spline was critical to the customer. The application saved $450,000 USD direct and $250,000 USD indirect cost savings annually.

c h a s s I s / h a r d w a r e

David (Dave) B. Reed P.E., who worked for then General Motors Corp. (GM) for 45 years in Product Engineering and helped develop many innovative automotive-plastics applications, has been named the eleventh recipient of the prestigious Lifetime Achievement award from the Automotive Division of the Society of Plastics Engineers (SPE®).

The Lifetime Achievement award recognizes the technical achievements of automotive executives whose work – in research, design, and engineering, etc. – has led to significant integration of polymeric materials on vehicles.

Dave Reed was selected as this year’s Lifetime Achievement award winner for his leading role on many of GM’s composite-bodied vehicles as well as numerous plastics innovations. He began his career at GM in 1963 while a

co-op student at then General Motors Institute (GMI, renamed Kettering University) and joined the Chevrolet® Materials Group in 1967. He received his B.S. degree in Mechanical Engineering / Materials Science and

completed his thesis on Development of Nylon Fuel Lines, in which he developed and recommended use of a more durable grade of nylon Type 11 fuel lines, which eventually led to industry-wide use

of the material in this application. In 1969, he was promoted to senior engineer with respon-sibility for all Chevrolet plastics, elastomers, gaskets, and adhesives. During this time he

introduced ethylene-propylene-diene monomer (EPDM) rubber for heater and radiator hoses on all Chevrolet vehicles, which doubled hose life. Reed also led the development

of painted thermoplastic polyolefin (TPO) bumper-filler panels, painted polyurethane (PUR) reaction-injection-molded (RIM) bumper fascias, as well as polycarbonate (PC)

lenses for all Chevrolet and GMC® truck rear tail lamps. In 1977 he was promoted to staff engineer at Pontiac® Engineering where he was responsible for all Pontiac

plastics and elastomers.

Reed helped develop the composite body constructions for GM’s Pontiac Fiero® and Firebird® and Chevrolet Camaro® sports cars, as well as the Saturn® coupe and sedan, and the EV1® electric vehicle. In fact, five of the programs he worked on were named Grand Award winners in SPE’s annual Automotive Innovation Awards Competition, including 1974’s win for the front and rear bumper covers (fascias) on the Chevrolet Monza® subcompact – an application that in 1993 also received’ SPE’s Hall of Fame award; 1983’s win for exterior body panels on the Pontiac Fiero sports car; a second Fiero sports car win in 1986 for rear quarter windows; the 1990 award for exterior door panels on Saturn sedans; and 1996’s award for the structural battery tray on GM’s iconic EV1 electric vehicle.

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L i f e t i m e A c h i e v e m e n t

2 0 1 1 s p e a u t o m o t i v e I n n o v a t i o n a w a r d s c o m p e t i t i o n & G a l a

GM Retiree, Dave Reed Named SPE® Automotive Lifetime Achievement Winner for Auto Plastics ContributionsGM Retiree, Dave Reed Named SPE® Automotive Lifetime Achievement Winner for Auto Plastics Contributions

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Before retiring from GM in 2008, Reed led the development of enhanced interior materials introduced on the Cadillac® SRX, STS, and CTS luxury vehicles. Not only were these vehicles highly acclaimed for the luxury, functionality, and good looks of their interiors, but they led to a new generation of interior technology integration for aesthetics, comfort, and safety at GM.

He also proposed GM’s partnership role in starting an industry-wide plastics recycling program with government assis-tance, which eventually became the United States Council for Automotive Research LLC (USCAR) Vehicle Recycling Partnership. He also led GM’s recycling team to share and optimize use of in-house plastics molding scrap across all GM’s molding operations, saving the automaker millions of dollars annually.

Reed has a long history of service to engineering societies. He is a recipient of SAE International®’s Forest R. McFarland Award for work on innovative technical sessions on such topics as Advances in Automotive Composite Body Panels, New Composite Cars, New Developments in Asian Plastics Applications, and Automotive Plastics Recycling. He also organized and led a technical session on Challenges in SMC Finishing at SPE’s own inaugural Automotive Composites Conference & Exhibition (ACCE), and has been a long-time director on the board of the SPE Automotive Division.

Dave Reed holds a patent in nanocomposites and two defensive publications. Since retiring, he has continued his dedication to plastics innovations as a consultant.

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their owners.

® Chevrolet Monza & Camaro, Pontiac Fiero & Firebird, Saturn, EV1, Cadillac SRX, STS, & CTS, & GMC, are registered trademarks of General Motors Co.

® SAE International is a registered trademark SAE International.

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Transmission Components in FluoroelastomersGeneral Motors Co. 2011 MY All GM Vehicles using 6L45,

6L50, 6L80, & 6L90 transmissions

Low-Cost Automated Preform Fabric AssemblyJiangsu Xinri E-Vehicle Co. Ltd.

2011 MY XR-EV05 electric delivery vehicle

System Supplier: Advanced Fiber Materials Technologies Co. Material Processor: Advanced Fiber Materials Technologies Co. Material Supplier: Owens Corning Resin: Araldite® Low-Viscosity LY 564 EpoxyTooling Supplier: Advanced Fiber Materials Technologies Co.

This new approach of using hook and loop fasteners on both sides of fiber plies leads to low-cost, 3D composites with increased strength and enable automation for layup of prepreg / preform fabrics. The new materials are able to make next-generation composites with a stronger interlaminate strength, impact resistance, compression strength, fatigue strength, bolt-hole strength, and bonding/connection strength for resin-transfer molding. The result is much faster ply layup due to easy handling of the plies. Use of advanced composites can reduce weight 40%, direct costs 50%, and indirect costs 30% vs. previous technology.

System Supplier: Robert Bosch LLC Material Processor: Freudenberg-NOKMaterial Supplier: Freudenberg-NOK Resin / Process: FluoroXprene® B FKM & ETFE / Injection moldingTooling Supplier: Freudenberg-NOK

Replacing both injection molded PA and conventional rubber, a new multi-patented fluoropolymer offers the chemical resistance of FKM with the rapid processing of thermoplastics. It also provides excellent compression set over the range of application temperatures, good permeation and fluid resistance vs. traditional fluorinated TPVs and TPEs, while solving a warranty issue and preventing seal failure, which can lead to electrical shorts. The unique 2-phase morphology of the material allows the ratio to be manipulated to produce either TPV or TPE formulations. Zero-waste, single-cavity direct injection leads to no scrap.

m a t e r I a l s

EP Biobased Polyester PolymerToyota Motor Co.

2011 MY Toyota® Prius® “A” Alpha station wagon

System Supplier: Kojima Press Industry Co., Ltd. Material Processor: Howa Plastics Co., Ltd. Material Supplier: DuPont Automotive Resin / Process: Sorona® EP 2045 PTT / Not statedTooling Supplier: Not Stated

This is the first use of polytrimethylene terephthalate (PTT), an entirely new thermoplastic polyster, which also happens to be biobased. This high-tem-perature thermoplastic polyester delivers improved performance (vs. PBT and PET), including higher stiffness and strength, higher use temperature but lower melt temperature at a lower specific gravity. Despite the fact that it contains 45% glass, it provides excellent surface finish, allowing elimination of a paint operation and the VOCs and costs associated with painting. In addition, its biobased content provides for CO2 reduction and a more sustainable solution.

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Volcanic-Filler Pillar TrimHyundai-Kia Automotive Group 2011 MY Kia® Pride® subcompact &

Kia®Optima® mid-size sedan and Hyundai® Elantra® compact car

Anti-Stain Finish for Cloth SeatsHyundia-Kia Automotive Group

2011 MY Hyundai® Soul® CUV & Kia® Optima® mid-size sedan

System Supplier: Kolon Glotech, Inc. Material Processor: Kolon Glotech, Inc. Material Supplier: Kolon Glotech, Inc. Resin: Cleantex® Innoclean® PolyesterTooling Supplier: Kolon Glotech, Inc.

Materials that typically soil and stain cloth are easily cleaned off even after significant wear takes place. Moisture-barrier, antistatic, and odor-resistant properties are also retained after wear. The improved fluoroalkyl resin coating uses the same pad/spray application method as previous technology while reducing costs 15%.

System Supplier: Plakor Co. Ltd.Material Processor: Plakor Co. Ltd.Material Supplier: Hyundai EP Co. Ltd. Resin / Process: Supol® HL345CL PP / Injection moldingTooling Supplier: Not Stated

This lightweight, injection-molded PP pillar trim provides the texture and appear-ance of more costly fabric-wrapped trim through use of a unique filler combina-tion consisting of volcanic rock, fiber pile, and glass spheres replacing talc-filled PP and fabric-wrapped PP. No special tooling was requiired but process control was important so as not to crush the glass spheres and to distribute the fiber pile evenly during compounding and molding. A 10% weight and a 50% direct cost savings was achieved. Other benefits gained from using the volcanic mineral are that it emits negative ions (to reduce pollutants) and far-infrared energy.

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Mirror-Shell BracketGeneral Motors Co.

2010 MY Chevrolet® Equinox® CUV

System Supplier: Magna International Inc. Material Processor: Magna International Inc. Material Supplier: Asahi Kasei Plastics North America Inc. Resin: Thermylene® P7-60FG-0790 BK711 PPTooling Supplier: Not Stated

By replacing glass-reinforced PBT and PET with this high strength and stiffness PP material, a 15% weight savings and $0.76 USD cost savings is achieved. Excellent vibration-dampening characteristics were also important in the application. The material has since been expanded into folding mirrors where it also meets the durability requirements.

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Recycled Materials from Gulf of Mexico Oil SpillGeneral Motors Co.

2011 MY Chevrolet® Volt® extended-range EV

System Supplier: GDC Inc.Material Processor: Not StatedMaterial Supplier: Mobile Fluid Recovery, Inc. Resin / Process: Enduraprene® 2395 PP/PE/SBR / Multiple Tooling Supplier: Not Stated

This project demonstrates how engineers came to aid the Gulf of Mexico coast community to improve the response efforts to the oil spill and to conserve resources. Air baffle components were molded from 100%-recycled material comprised of: 25% PP Gulf oil-boom absorbent (recycled previously from automotive waste), 25% used Milford Proving Ground test tires, and 25% polymer packaging aids from other General Motors’ facilities, plus 25% post-consumer PE bottles.

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Loadfloor Using Coconut FeltFord Motor Co.

2012 MY Ford® Focus® BEV

System Supplier: Autoneum Holding AG Material Processor: Aftech LL & Hobbs Bonded Fibers Material Supplier: Natural Composites, LLC Resin / Process: PP / Not StatedTooling Supplier: Not Stated

This loadfloor uses coconut fiber agricultural waste for reinforcement of the polymer matrix. The coir fibers are carded and needle punched to create a mat and then calendared inline to achieve the desired thickness before being die-cut to shape and assembled with other components. This provides income to farmers and reuses a material that otherwise would have little market usefulness.

Reduced-VOC HydrographicsChrysler Group LLC

2011 MY Chrysler® 300 luxury sedan

System Supplier: CpK Interior ProductsMaterial Processor: Dongguan Taica Hirosawa Technologies Co., Ltd. & Hirosawa Automotive TrimMaterial Supplier: Taica Corp. Resin / Process: PC/ABS / Injection-molded substrate & hydrographics coatingTooling Supplier: Not Stated

The supplier’s proprietary E-Cubic process eliminates the need for top coating and reduces VOCs vs. conventional hydrographics, paint, and in-mold film use while providing unique decorating features, including dual gloss levels and 3D texturing.

Renewably Sourced PA for Biodiesel Fuel LinesFiat S.p.A.

2011 MY Fiat® Diesel engines, various models

System Supplier: HutchinsonMaterial Processor: HutchinsonMaterial Supplier: DuPont AutomotiveResin / Process: Zytel® RS 1610 PA 10/10 / ExtrusionTooling Supplier: Not Stated

This is the first automotive use of PA 10/10 and the first bio-based PA 10/10 application. It is used in a diesel fuel line replacing PA 12. The bio-based resin provides superior temperature and chemical resistance, as well as heat-aging performance in biodiesel fuel blends vs. PA 12. This specific composition also contains a minimum of 60% bio content by weight for a more sustainable solution.

33


Bio-Polyurethane Foam in Automotive Seating Head RestraintsFord Motor Co.

2011 MY Ford® Fusion® & Lincoln® MKZ® sedans

System Supplier: Lear Corp.Material Processor: Lear Corp.Material Supplier: Lear Corp.Resin: Bio-Based PURTooling Supplier: Lear Corp.

This head restraint foam uses 13 - 16% by weight (equivalent to 13-26% by volume) soybean oil-derived polyol to replace petroleum-based reactants in this MDI catalyzed polyurethane. Ford’s use of bio-based foam in head restraints, seat cushions, and seat backs has helped the company reduce its petroleum usage by more than 3-million lb annually and carbon dioxide emissions by over 15-million lb. The switch was cost neutral.

Bio-Foam for Instrument PanelsFord Motor Co.


System Supplier: Automotive Component Holdings LLC Material Processor: Automotive Component Holdings LLCMaterial Supplier: BASF Corp. Resin / Process: Elastofoam® Balance 27730 & 27731 PUR Foam / Foam in placeTooling Supplier: Not Stated

The use of bio-based castor beans for the polyurethane foam in this applica-tion provides a partially sustainable alternative to conventional urethanes with 100% petroleum inputs. By reducing petroleum-based content, the carbon footprint of vehicles is reduced, thanks to the CO2 sequestering plants do during their growth cycle. The bio-foam also provides softness for this foam-in-place application, which required no tooling changes and was cost neutral.

e n v I r o n m e n t a l

The interiors of the 2011 model year (MY) Chrysler® 200 and Dodge® Avenger® mid-size sedans, which were developed and launched as part of vehicle facelifts in just over a year, won Chrysler Group LLC and its interiors supplier, Faurecia, the 2011 Vehicle Engineering Team Award (VETA) from the Automotive Division of the Society of Plastics Engineers (SPE®) as part of the group’s 41st-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. James N. Lyijynen, system responsible – Interior Cockpit, System & Component Engineering, at Chrysler Group LLC will accept the award on behalf of all OEM and supplier team members during SPE’s annual Automotive Innovation Awards Gala.

Unlike other SPE executive awards, VETA recognizes the technical achievements of entire teams comprised of automotive designers and engineers, tier integrators, materials suppliers, toolmakers, and others whose work—in research, design, engi-neering, and/or manufacturing—has led to significant integration of polymeric materials on a notable vehicle. This is the fifth time in eight years that the award has been presented. The first winner was Porsche AG for the 2004 MY Porsche® Carrera® GT supercar, and Ford Motor Co. has won in three previous years with, respectively, its 2009 MY Ford® Flex™ cross-over-utility vehicle (CUV), 2010 MY Ford Taurus® sedan, and 2011 MY Ford Explorer® sport-utility vehicle (SUV).

Chosen by a panel of Blue Ribbon judges and SPE Automotive Div. board members from nominations by each of the Detroit Three automakers, the winning team was selected, in the words of one judge, “because of the incredibly tight timing and the highly integrated team approach taken with key suppliers.”

All new interiors for both the 2011 Dodge Avenger and Chrysler 200 sedans were developed in a record 54 week time period, just over 12 months from surface freeze to start of production (SOP). The previous-generation Chrysler Sebring® and Dodge Avenger interiors were developed on a 30 month time line. Partly as a result of the 2008 global economic downturn and the ownership change of Chrysler Group LLC in 2009, the new company was at risk of not having a competitive sedan in the D segment, the second-largest segment in the automotive market. To remain competitive, Chrysler Group needed a solution that could be brought to market rapidly.

Not only did the team face a compressed development cycle, but other challenges also presented themselves, including ongoing product changes (e.g. late theme and feature/content changes); no plan for a design/validation test phase or prototype vehicles; short lead times to build (hard) production tooling and limited tool-trial runs planned before launch; as well as unknown model year phase out / phase in timing at the start of the program.

To help the team create two distinct interior “personalities” for the two vehicles in the compressed timeframe, three key factors were used: a craftsmanship benchmarking report from Chrysler Group, Faurecia’s perceived-quality methodology, and use of a number of carryover components (e.g. a common cross-car beam, instrument panel retainer, glove-box door, and drive-side knee bolster). The team had strong support from both organizations. For example, there was full respect for surface freeze dates, materials to be used for the interior components were confirmed by mid-November 2009 with no further changes allowed; and between tool kickoff and first parts and between tool-tuning loops/iterations no changes were allowed to help freeze the product definition and keep it there. Further, a full complement of virtual validation tools was used. And with regard to the expedited tooling schedule, critical tools were sourced locally, and rapid in-mold graining tools—achieved with nickel-shell tool technology—were used.

34

v e h i c L e e n g i n e e r i n g


Chrysler Group LLC Wins 2011 Vehicle Engineering Team Award from SPE® Automotive Division

35

Dedicated Chrysler support for both surface approvals and graining, and executive oversight by both the automaker and Faurecia helped support the timeline and facilitated rapid decision making. Co-location of a dedicated Chrysler console stylist at Faurecia, and management of Class A design for consoles and door trim by Faurecia employees, plus a daily “war room” huddle kept both companies fully engaged in the process. And owing to Faurecia’s global organization, team members in the U.S., Mexico, France, India, and China participated, allowing for a true 24/7 response to the development effort.

Thanks to the unique collaboration and team discipline, the new Chrysler 200 and Dodge Avenger sedans launched with beautifully updated interiors featuring premium materials, ambient lighting, and other accents, all at a lower cost than the outgoing models. Other benefits of the collaboration included halving the normal delivery time; use of nickel-shell tools, which allow for quick and accurate duplication as production demands increase but provide a quality equivalent to electroplated tooling; higher quality parts with smaller and more accurate tolerances; and an increase in the perceived quality for grain definition. To prepare for sales globally, production of interior components now takes place in the U.S., Mexico, Spain, and China to serve worldwide demand. The interior of both vehicles makes use of 183 primary tools for both injection and thermoforming and represents the first production application of rapid nickel-shell in-mold grain tools.

v e h i c L e e n g i n e e r i n g


® Chrysler 200 and Dodge Avenger are registered trademarks of Chrysler Group LLC.

photo credit: Chrysler Group LLC

TeAm AwArdTeAm AwArd

36


Crash-Boxes for Truck-Cabin Occupant ProtectionVolvo-Eicher Commercial Vehicle Pvt Ltd. 2011 MY India 7T LCV commercial truck

Reinforced Airbag Lid in Foam (RALF)Ford Motor Co.


System Supplier: Faurecia Interior SystemsMaterial Processor: Faurecia Interior SystemsMaterial Supplier: Not Stated Resin / Process: PET & PUR / Not StatedTooling Supplier: Not Stated

RALF technology is an optimized instrument panel / passenger airbag door system that uses a reinforced structural 3D-skeleton of PET mesh textile and polyurethane foam lid. RALF replaces the traditional metal or plastic airbag lid door and offers much improved airbag lid positioning with less risk of windshield breakage. It offers significant weight savings over traditional foam-in-place airbag construction and is cost-neutral.

System Supplier: Machino Plastics Ltd.Material Processor: Machino Plastics Ltd. Material Supplier: SABIC Innovative Plastics Resin: Xenoy® 1102 PC/PBTTooling Supplier: Machino Plastics Ltd.

Injection-molded PC/PBT was used to form left and right side crash boxes that allowed the commercial truck OEM to meet the very high (30kJ) impact energy of this crash requirement in India. The versatile design allows both left- and right-hand parts to be be molded from the same tool while reducing weight 30% vs. the previous steel system,

s a f e t y

38


Undertray with Pedestrian-Safety FunctionalityFord Motor Co.

2011 MY Ford® C-Max® world car

System Supplier: FaureciaMaterial Processor: FaureciaMaterial Supplier: SABIC Innovative Plastics Resin / Process: Xenoy® iQ1103R PC/PBT / Injection moldingTooling Supplier: Not stated

The undertray structure was uniquely designed with “spring-back action” to help the vehicle achieve a Euro-NCAP 5 Star rating while eliminating the need for a separate lower spoiler, saving 1.5-2.0 kg of weight and $10-15 USD in extra cost. The lightweight corrugated structure incorporates other functional requirements, including air guides for air intake to cool the tower assembly and to meet stone chipping requirements. The PC/PBT resin used to injection mold this part is upcycled from post-consumer plastic waste, reducing landfill usage and hydrocarbon-fuel consumption while providing excellent impact resistance.

Pedestrian-Safety Upper Load PathLand Rover

2011 MY Range Rover® Evoque® CUV

System Supplier: Magna International Inc. Material Processor: Magna International Inc. Material Supplier: SABIC Innovative Plastics Resin / Process: Xenoy® iQ1103R PC/PBT / Injection moldingTooling Supplier: Not stated

This 1-piece injection-molded fascia reinforcement eliminates the need for support brackets and offers tuned stiffness to control lower-leg kinemat-ics during pedestrian impact with this cross-over utility vehicle (CUV). The fascia reinforcement, also tuned for pedestrian protection, eliminates the need for an additional energy absorber in front of the bumper beam. Good lateral rigidity and creep behavior minimizes sag during sun load. Molded-in air intake guides bring cooling air to the intercooler. The upcycled PC/PBT material used in this application is reclaimed from post-consumer plastic waste, reducing landfill burden and hydrocarbon fuel needs. The application reduced weight 20% by eliminating the metal bracket. Another 0.5-1.0 kg of weight was saved by eliminating the need for the foam energy absorber.

s a f e t y

The SuperPlug® integrated composite door-hardware module—which first debuted on 1997 model year (MY) Chevrolet® Venture® and Malibu®, Pontiac® Transport®, Oldsmobile® Silhouette® and Cutlass®, and Opel® Sintra® vehicles from then General Motors Corp. (GM)—was selected as the 2011 Hall of Fame winner of the Automotive Division of the Society of Plastics Engineers’ (SPE®’s) 41st-annual Automotive Innovation Awards Competition. To be considered for a Hall of Fame award, an automotive-plastic component must have been in continuous service in some form for at least 15 years and preferably have been widely adopted within the automotive or ground-transportation industries. As the first all-plastic integrated door-hardware module, it reduced components and fasteners by up to 75% by molding features into a single gas-assist injection-molded composite frame that literally “plugged-into” the inner door on the vehicle-assembly line, improving ergonomics and quality, saving labor time and costs, and reducing warranty claims.

According to SPE Hall of Fame committee co-chair, Nippani Rao, president, Rao & Associates, “The success of the SuperPlug program is easily seen when you consider that industry sources estimate that over 250-million integrated composite door-hardware modules have been produced globally by all suppliers since 1997 and used on over 60-million vehicles worldwide. At an average of 5 pounds of plastic per module, that’s over a billion pounds of resin consumed in just this one automotive application. That makes it an ideal example of the type of component that warrants an SPE Hall of Fame award.”

The module was jointly developed during a 5-year program that started in 1990 by then Delphi Interior & Lighting Systems (at the time a division of GM, and whose business, production, and patents have since been transferred to Inteva Products, LLC) and GE Plastics (now SABIC’s Innovative Plastics business unit). The collaboration this program fostered between the suppliers would eventually become a model of close business and technical alliances between members of the automotive supply chain.

At that time, the interior of conventional automotive doors featured dozens of separate components and subassemblies that were installed individually and had to be bolted, screwed, welded, and/or riveted into place in a labor-intensive process. Delphi had previ-ously been successful with its steel back-plate door modules, which had moved assembly labor out of GM’s vehicle assembly plants and into the supplying plant. However, these modules did not eliminate labor; they only relocated it to a facility with more efficient assembly operations. As engineers at Delphi’s Advanced Development Group began working on the next-generation door-hardware module, they wanted to minimize labor, not just relocate it, and they proposed doing so by taking advantage of the design flexibility and parts consolidation possible with injection-molded plastics. Additional program goals were to meet GM’s targets for mass, parts, and cost reduction; investment savings; and shorter development times.

Through an iterative design process, using finite-element analysis, moldfilling analysis, design of experiments, design for assembly, process optimization, and extensive real-world production validation, a new design was created that could be molded to replace the sheet-metal module back plate with a single-piece modular frame. Gas-assist injection molding—which produces hollow sections in an otherwise solid-plastic part via injected gas that hollows out channels—was attractive for the module since it could produce lightweight parts with excellent stiffness and dimensional stability in a cycle time of 80 seconds without need for special (and costly) tooling features like slides. And a new grade of glass-reinforced Xenoy* polycarbonate/polybutylene terephthalate (PC/PBT) resin, specially developed by GE for the application, was specified for stiffness, strength, impact resistance, compatibility with automotive chemicals, and to improve energy absorption of the door panel vs. steel.

With the new module, many key components—including wire harnesses, the door handle, window guidance channels, stereo speakers, and electric motors—were snapped into place at Delphi’s assembly plant and pretested before being shipped to GM’s assembly lines. This improved the OEM’s material-handling situation and potentially reduced subsystem rejects by up to 96%. The modular design not only improved assembly but also made later serviceability/repair much simpler. Assembly ergonomics were

40

h A L L o f f A m e


SuperPlug® Door Hardware Module is 2011 Hall of Fame Winner at SPE® Auto Innovation Awards CompetitionSuperPlug® Door Hardware Module is 2011 Hall of Fame Winner at SPE® Auto Innovation Awards Competition

41

further improved, since line workers no longer had to “fish” components into the door in various locations to be riveted or bolted in place, and the molded frame eliminated the die grease and sharp edges typical of traditional metal components. The module even had a molded-in carrying handle that made it easier for workers to remove it from shipping crates and position it inside the door cavity. With fewer attachments needed, fewer tools were required for assembly, lowering invest-ment costs and assembly-line labor time by 3 minutes, netting a 10% cost savings.

By molding features into the plastic carrier, over 40 metal parts plus 15-25 fasteners were replaced with a single composite module and 5-6 fasteners. Hence, labor at all points in the build process was reduced, fewer components needed to be purchased, inventoried, and used, and a host of other benefits were also gained including over 50% reduction in warranty costs thanks to parts reductions and easier repair. Additionally, replacement of metal parts and fasteners with sound-absorb-ing plastics reduced high-frequency vibration and led to quieter motor/gear operations and hence doors with lower buzz/squeak/rattle (BSR) values. Scrap was reduced, since the new gas-assist process had a 99% yield quality. Weight was reduced approximately 3.3 lb/1.5 kg per door, which helped improve fuel economy and lower emissions. And the module, which was fully melt reprocessable once components were unloaded, met European recyclability requirements.

Interestingly, at the time it launched, the SuperPlug module represented three untried technologies: it was the first complex part ever produced with gas-assist injection molding; it used a new grade of glass-reinforced PC/PBT; and the component itself represented the highest level of parts integration then achieved with door modules.

So significant was the technology developed for this program that nine key patents were issued between October 1993 and June 1998. The module also won numerous prestigious awards, including: SPE ANTEC’s Plastics Industrial Product Design Award; Modern Plastics International magazine’s Process Award; Plastics & Rubber Weekly (PRW) magazine’s Award of Excellence in Transportation Category; the International Body Engineering Conference’s (IBEC’s) Design Award; and Design Fax magazine’s Five-Star Product of the Month Award.

The 2011 SPE Automotive Division Hall Of Fame committee was co-chaired by Nippani Rao, Rao & Associates and Dave Reed, retired, General Motors Corp. Committee members include Bonnie Bennyhoff, ExxonMobil Chemical; Terrence Cressy, DuPont Automotive; Fred Deans, Allied Composite Technologies, LLC; John Fialka, Styrolution Group GmbH; Ed Garnham, retired, General Motors Corp.; Anthony Gasbarro, Marubeni America Corp.; Jeffrey Helms, Ticona Engineering Polymers; Norm Kakarala, Inteva Products, LLC; James Kolb, American Chemistry Council; Mark Lapain, Magna International Inc.; Josh Madden, retired, General Motors Corp. and Volkswagen North America Inc.; Gordon Miesel, retired, Ashland, Inc.; Allan Murray, Allied Composite Technologies, LLC; Kevin Pageau, Tegrant Corp.; Tom Pickett, General Motors Co.; Irv Poston, retired, General Motors Corp.; Suresh Shah, Delphi Corp.; Venkatakrishnan Umamaheswaran, SABIC Innovative Plastics; and Bill Windscheif, Advanced Innovative Solutions, Ltd.

h A L L o f f A m e

A w A r dA w A r d


® Chevrolet Venture and Malibu, Pontiac Transport, Oldsmobile Silhouette and Cutlass, and Opel Sintra are registered trademarks of General Motors Co.

® SuperPlug is a registered trademark of Inteva Products, LLC.* Xenoy is a trademark of SABIC Innovative Plastics IP B.V.

42


p r o c e s s , a s s e m B l y & e n a B l I n G t e c h n o l o G I e s

Composite Wheel WeightsGeneral Motors Co.

2011 MY Cadillac® CTS sedan & Corvette® sports car

System Supplier: ESYS AutomationMaterial Processor: 3MMaterial Supplier: 3M Resin / Process: 3M proprietary / ExtrusionTooling Supplier: ESYS Automation

This innovation uses extrusion of a highly filled polymer and automa-tion equipment to provide significant product flexibility and performance improvements that, for the first time, enable fully automated tire balance weight installation. Replacing stamped, painted steel parts that required manual installation, and reducing the SKUs from 24 to 1, the innovation uses large spools of wheel weights in tape form with an adhesive backing that can be automatically cut and applied very accurately to reduce labor, scrap, appli-cation cycles, and an average of 0.3-0.5 grams of excess weight per wheel.

Advanced Material Characterization for Interior PartsFord Motor Co.

2012 MY Ford® Explorer® SUV

System Supplier: Not StatedMaterial Processor: Not Stated Material Supplier: Not StatedResin: Not StatedTooling Supplier: Not Stated

Use of advanced materials characterization of plastics enables improved ana-lytical modeling and therefore proveout of parts molded from these materials. Advanced analysis tools are used to predict crack propagation, high strain-rate behavior, anisotropic properties of glass-filled plastics, creep data, and more for injection-molded thermoplastics, enabling engineers to design closer to the theoretical limits of materials and saving 10-20 % weight for interior plastic components. This leads to a 5-15 % reduction in material costs and a $500,000 USD reduction in testing costs per program.

43


1-Piece Structural TPO Aero Rocker MoldingFord Motor Co.

2012 MY Ford® Edge® SUV

Integrated Liftgate Trim Grab HandleFord Motor Co.

2012 MY Ford® Focus® compact hatchback

System Supplier: NYX Inc. Material Processor: NYX Inc.Material Supplier: Not StatedResin / Process: PP / Injection moldingTooling Supplier: Aalbers Tool

Through design and tooling innovations, the injection-molded polypropylene liftgate grab handle was molded in a single piece vs. previous 2-piece assem-blies thanks to 3 large cavity-side slides in the tool. The innovation saved 0.1 lb and $0.60 USD / vehicle.

System Supplier: ABC GroupMaterial Processor: ABC GroupMaterial Supplier: LyondellBasell Advanced Polyolefins USA, Inc. Resin: Sequel® TYC 852P TPOTooling Supplier: Delta Tool

A patented, non-traditional injection molding process, where a chemical foaming agent is combined with TPO, was used to produce this rigid 1-piece structural component that met customer requirements while maintaining a Class A surface and lowering weight and part count vs. previous processes. The innovation saved 2 parts and 3.86 lb / vehicle, resulting in a $7.6MM USD direct cost savings and an additional $1.0MM USD estimated indirect cost savings due to reduced part complexity and assembly-plant labor.


44


MuCell® Instrument PanelFord Motor Co.

2012 MY Ford® Escape® compact SUV & Kuga® compact CUV

System Supplier: FaureciaMaterial Processor: FaureciaMaterial Supplier: SABIC Innovative Plastics & Flint Hills ResourcesResin / Process: Stamax® EXRP-49 30YK270 & AP3335-HF long glass / 10% reactor-grade talc-filled PP / Microcellular injection moldingTooling Supplier: Lamko

This instrument panel is the largest automotive component and first IP molded with the patented MuCell injection-molding process. That innovation was combined with 10% reactor-grade talc-filled PP, to create a microcellular foam part that reduced weight over 1 lb, lowered cycle times by 15% and clamp tonnage by 45%, and saved an estimated $3 USD / vehicle vs. solid injection molding.


45


Battery PackGeneral Motors Co.

2011 MY Chevrolet® Volt® extended-range EV

System Supplier: General Motors Co.Material Processor: MANN+HUMMEL GmbH Material Supplier: BASF Corp. Resin / Process: Ultramid® 1503-2F PA 6/6 33% GF, HS / Injection moldingTooling Supplier: Omega Corp.

Thermoplastic battery frames are an integral part of electric-vehicle thermal management, channeling coolant to and from the cells. The use of injection-molded hydrolysis-resistant PA 6/6 for thermal-cycling management is a lightweight enabling material for this design, which required exacting manu-facturing consistency and high levels of repeatability and reproducibility.

Ni-MH Battery Package for HEVVolkswagen AG

2010 MY Volkswagen® Touareg® hybrid CUV

System Supplier: Sanyo ElectricMaterial Processor: Not StatedMaterial Supplier: SABIC Innovative PlasticsResin / Process: Noryl® SE100P M-PPE / Injection moldingTooling Supplier: Not Stated

Injection molded modified-PPE resin was used for this compact Ni-MH battery module package, providing greater dimensional accuracy than glass-reinforced PBT and lower weight vs. glass-reinforced PPE/PS. The resulting assembly is 50% lighter than it would have been in die-cast aluminum and 5-10% lighter vs. competitive GR-PBT or GR-PA, making it the best material choice for the required properties at low weight.

p o w e r t r a I n

Plastic Transmission Accumulator PistonChrysler Group LLC

2012 MY All Chrysler Vehicles with Automatic Transmissions

System Supplier: Chrysler Group LLCMaterial Processor: Freudenberg-NOK Sealing TechnologiesMaterial Supplier: Chevron-Phillips Chemical Co. LLCResin / Process: Ryton® R-Y-120 PPS / Injection moldingTooling Supplier: Freudenberg-NOK Sealing Technologies

This molded plastic transmission accumulator piston was designed around the current application so that the bore, seal rings, and return springs did not have to be changed and it was a drop-in replacement. Maximum effort went into material choice (PPS) and model shape to achieve the appropriate toughness to handle time, temperature, pressure, and combined cycling to create a 200,000-mile capable piston. The resulting part is 29 g vs. typical 47 g for aluminum pistons. A direct thermoplastic injection technology was developed to produce the parts, resulting in zero material waste through the use of a single-cavity design. The process allowed for a 33% improvement in cycle times and reduces the total floor space required by 20% over previous multi-cavity processes. The change in phi-losophy also eliminated the need for material regrind / reclamation equipment and lowered total capital expenditures. The innovative approach used here has allowed for a modular business cell that is adaptable to large market-volume fluctuations.

47


p o w e r t r a I n

Plastic Oil StrainerHyundai-Kia Automotive Group

2011 MY Hyundai® i10® subcompact

System Supplier: Sambo MotorsMaterial Processor: Taeyoung ChemicalMaterial Supplier: Desco Resin: Glass-Filled PA 6/6Tooling Supplier: Dongshin Hydraulics

Moving from traditional welded steel to plastic for the oil strainer saved 100 g of weight, a 50% reduction, for improved fuel economy. Vehicle testing (at over 200,000 km of driving) confirms the durability of the application. A 35% glass-reinforced polyamide 6/6 was used for strength and chemical resistance and was overmolded onto the steel-mesh screen for a stronger bond and increased durability.

48

TheHallofFameAwardisgivenannuallyfor

anapplicationthathasbeenincontinuoususe

for15yearsormore,andhasmadeasignficant

andlastingcontributiontotheapplicationof

plasticsinautomobiles.hall of fame By year

YEARRECOGNIZED OEM APPLICATION MATERIAL2010 GeneralMotorsCo. Front&RearTPOBumperFascias TPO

2009 GeneralMotorsCo. ThermoplasticVerticalBodyPanel MPPE/PA

2008 ChryslerLLC RearSeatCushion PURFoam

2007 FordMotorCo. RadiatorEndTank PA6/6

2006 GeneralMotorsCorp. ThermoplasticFrontGrille ABS

2005 Porsche ThermoplasticIntakeManifold PA

2004 FordMotorCo. BoxBeamBumper PC/PBT

2003 GeneralMotorsCorp. Dual-DensityEnergyAbsorbingBumperSystem PP

2002 GeneralMotorsCorp. Mini-WedgeLatchandDoor-LockActuator PA

2002 GeneralMotorsCorp. Wiper-SystemTransmissionHousing PA

2001 GeneralMotorsCorp. Instrument-PanelRetainer SMA

2000 VolkswagonAG FuelTank HDPE

1999 FordMotorCo. HydraulicClutchActuator PA

1998 Citroën FanShroud PA

1997 FordMotorCo. TransmissionSeal PPS

1996 GeneralMotorsCorp. FrontFenders RIM-PUR

1995 GeneralMotorsCorp. Guide-FlexEnergyAbsorbers EVA

1994 FordMotorCo. HeadlampAssembly PC

1993 GeneralMotorsCorp. Front/RearBumperCovers RIM-PUR

1992 GeneralMotorsCorp. CompositeExteriorBodyPanels SMC

1991 GeneralMotorsCorp. TiltSteering-WheelCenteringSphere Acetal

1990 GeneralMotorsCorp. TransverseLeafSpring Epoxy

1989 AmericanMotorsCorp. BatteryCase PP

1988 FordMotorCo. WindshieldInterlayer PVB

1987 GeneralMotorsCorp. Grill-OpeningPanel SMC

1986 ChryslerCorp. HeaterHousing PP

1985 ChryslerCorp. Disc-BrakePiston Phenolic

1984 GeneralMotorsCorp. Front-FenderWheelLiner PP

1983 GeneralMotorsCorp. EmissionsControlCanister PA

50

YEAR OEM APPLICATION MATERIAL2010 FordMotorCo. Diesel-ExhaustFluid(DEF)System Multiple

2009 GeneralMotorsCo. ShieldedPlasticCaseRadio PC/ABS

2008 BMW Twin-SheetBlow-MoldedFuelSystem HDPE

2007 GeneralMotorsCorp. BacklightingwithColor-ConvertingPlastic PC

2006 DaimlerChrysler Blow-MoldedFront-&Rear-BumperSystem TPO

2005 HondaMotorCo. CompositeIn-BedTrunk SMC

2004 FordMotorCo. DoorTrimwithIntegratedAcoustic PP ChamberandSubwoofer

2003 DaimlerChrysler RoofModule PCCopolymer

2002 DaimlerChrysler ExtrudedPolymerFilmFascia Multi-LayerIonomer

2001 GeneralMotorsCorp. NanocompositeTPO NanocompositeTPO

2000 FordMotorCo. ControlledEnergyManagementBumperIsolator HDPE

1999 DaimlerChrysler FanShroudandReservoirAssembly PP

1998 MitsubishiMotors “I”SectionBumperBeam PP-GMT

1997 FordMotorCo. “CarpettoCarParts” PA

1996 GeneralMotorsCorp. StructuralBatteryTray PP-GMT

1995 FordMotorCo. IntegratedFront-EndSystem SMC

1994 GeneralMotorsCorp. ThermoplasticAir-IntakeManifold PACopolymer

1993 FordMotorCo. Front-SuspensionStabilizerLink POM

1992 ChryslerCorp. Instrument-PanelSystem PP-GMT,MPPE,PP&PUFoam

1991 ChryslerCorp. IntegratedChild’sSeatandTopImpactPad PP-GMT,ExpandedMPPE

1990 GeneralMotorsCorp. ExteriorDoorPanel PC/ABS

1989 ChryslerCorp. CompositeWheel SMC/XMC

1988 GeneralMotorsCorp. FrontFender MPPE/PA

1987 GeneralMotorsCorp. Quarter-PanelAssembly–Sportside SMC

1986 GeneralMotorsCorp. QuarterWindow PMMA

1985 GeneralMotorsCorp. WindshieldwithAnti-LacerativeLayer PolyvinylButyral/PEFilm

1984 FordMotorCo. DriveShaft Vinylester/Graphite/Glass

1983 GeneralMotorsCorp. ExteriorBodyPanels SMC,RIM,RRIM,&TPO

1982 GeneralMotorsCorp. TailgateAssembly SMC

1981 FordMotorCo. Radiator-CoreEndCaps PA

1980 GeneralMotorsCorp. Rear-AxleLeafSpring Epoxy

1979 FordMotorCo. Grille-OpeningPanelAssembly SMC

1978 GeneralMotorsCorp. Bucket-SeatFrame SMC

1977 FordMotorCo. InstrumentPanel

1976 FordMotorCo. FenderAprons PP

1975 AmericanMotorsCorp. One-PieceJeepTop PC

1974 GeneralMotorsCorp. FasciaandRearBumperCover RIM-PUR

1973 FordMotorCo. Block-HeaterMotorHousing

1972 GeneralMotorsCorp. RadiatorFan-ShroudAssembly PP

1971 FordMotorCo. TransmissionReactor Phenolic

Grand award wInner By year

51

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plaqUe & trophy o r d e r f o r m

TO MAY 2012

BonnieBennyhoffExxonMobilChemical

FredDeansAlliedCompositeTechnologies

EdGarnhamGeneralMotors(retired)

ChuckJarrettSABICInnovativePlastics

PeggyMalnatiMalnati&Associates

JayRaisoniAdellPlastics

TO MAY 2013

JaneAselageFordMotorCo.

SheldonBrownToyotaMotors

SusanColeMillerColeLLC

MikeMasserantFordMotorCo.

RonPriceGlobalPolymerSolutions

DaveReedDavidReedConsultingLLC

MikeWhitensFordMotorCo.

TO MAY 2014

BrianGrosserSamsung

NormKakaralaIntevaProducts

MarkLapainMagnaInternational

KevinPageauTegrantCorp.

NippaniRaoRaoAssociates

JackieRehkopfPlasanCarbonComposites

SureshShahDelphiCorp.

CHAIRAnthonyGasbarroMarubeniUSA

CHAIR-ELECTJeffreyHelmsTiconaEngineeringPolymers

VICE-CHAIRYvonneBankowskiFordMotorCo.

PAST-CHAIRJeffreyHelmsTiconaEngineeringPolymers

TREASURERJackieRehkopfPlasanCarbonComposites

SECRETARYMonicaProkopyshenChryslerLLC(Retired)

DIVISIONCOUNCILORTomPickettGeneralMotorsCo.

DIRECTORSEMERITUSJoshMaddenMaterialsEngineeringServices

AllanMurrayAlliedCompositeTechnologiesLLC

NippaniRaoChryslerLLC(Retired)

d I v I s I o n o f f I c e r s & e x e c U t I v e c o m m I t t e e

INNOVATIONAWARDSPROGRAMJeffreyHelmsTiconaEngineeringPolymers

ANTECTPCAnthonyGasbarroMarubeniUSA

AutoEPCONNormKakaralaIntevaProducts

MEMBERSHIPBillPippineTakataHoldingsLLC

NEWSLETTEREDITORKevinPageauTegrantCorp.

NEWSLETTERSPONSORSHIPTeriChouinardIntuitGroup,LLC

GOLFOUTINGFredDeansAlliedCompositeTechnologies

INTERSOCIETYJackieRehkopfPlasanCarbonComposites

SOCIAL SuzanneColeMillerColeLLC

BrianGrosserSamsung

ACCE,COMMUNICATIONS&WEBPeggyMalnatiMalnati&Associates

EDUCATIONMonicaProkopyshenChryslerLLC(Retired)

c o m m I t t e e c h a I r p e r s o n s

B o a r d o f d I r e c t o r s

52

society of plastics engineers a u t o m o t i v e d i v i s i o n

medIa / assocIatIon sponsorsAutomotive Design & Production Magazine

AutoFieldBlog

Automotive Engineering Int’l. Magazine

Automotive NewsWire

China Plastics & Rubber Journal

China Plastics & Rubber Journal, Int’l.

Composites Technology Magazine

CompositesWorld.com

Crain’s Plastics in Lightweight & Electric Vehicles Conference

High-Performance Composites Magazine

Modern Plastics India Magazine

Plastics Engineering Magazine

Plastics Technology Magazine

Plaspec Global Plastics Selector

Polymotive Magazine

Rubber World Magazine

SAE International

TPE Magazine

Ward’sAuto.com

The SPE Automotive Innovation Awards Gala would not be possible without the gracious support of our sponsors, who

underwrite the cost of this event. Hence, it is with great appreciation that we thank and acknowledge the contributions

of the 2011 SPE Automotive Innovation Awards Gala sponsors and other patrons for making this event a success.

Saluteto our SponSorS

Gala & afterGlow sponsorTicona Engineering Polymers

Gold sponsorsAmerican Chemistry Council – Plastics Division

DuPont Automotive

Faurecia Interior Systems

ExxonMobil Chemical Co.

sIlver sponsorsAdvanced Composites

Bronze sponsorsAsahiKasei Plastics North America, Inc.

BASF Corp.

Chevron Phillips Chemical Co.

DSM Engineering Plastics

Flint Hill Resources

Inteva Products LLC

JSP

LyondellBasell Industries

NYX Inc.

SABIC Innovative Plastics

Styrolution Group GmbH

advertIsInG only sponsorsAdell Plastics Inc.

Brose Fahrzeugteile GmbH & Co. KG

· They also realize that the automotive design and ... ments The snap-together design...

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