Vehicle Engineering Team Award

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W e l c o m e
to the 2011 Innovation
Awards Gala
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 passionate 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:
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Body Exterior
Body Interior
Chassis & Hardware
Lifetime Achievement Award
Materials
Environmental
Vehicle Engineering Team Award
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Safety
Hall of Fame
Past-Chair Award (SPE Automotive Division)
Process, Assembly & Enabling Technologies
Powertrain, and
The Grand Award
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 Helms
Jeffrey Helms
’10-’11 SPE Automotive Innovation Awards Program Chair
Ticona Engineering Polymers
4
Blue Ribbon Judges
Mike Brady
SCHEDULE OF EVENTS
5:00-6:30 pm Reception / Preview of
Nominated Parts & Vehicle Displays
_____________________________________________________________
6:30 pm Seating Begins
_____________________________________________________________
6:45-7:00 pm Welcome / Dinner
Reinforced Plastics magazine
Pam Brady
Reinforced Plastics magazine
Dale Brosius
High-Performance Composites & Composites Technology magazines
Alexander Buechler
Polymotive magazine
Suzanne Cole
Miller Cole LLC
Subi Dinda
Oakland University
Jeff Helms, Ticona Engineering Polymers
Bob Eller
and 2011 SPE Automotive Innovation Awards Program Chair
Teri Chouinard, Intuit Group
Maria Ciliberti, Ticona Engineering Polymers
John Fillion
_____________________________________________________________
7:00-9:00 pm Gala Program
Body Exterior
Tom Pickett, General Motors Co.
Body Interior
Yvonne Bankowski, Ford Motor Co.
Chassis & Hardware
Scott Klingler, Ticona Engineering Polymers
Lifetime Achievement Award
Robert Eller & Associates
Chrysler LLC (retired) & Engineering Society of Detroit
Ryan Gehm
Automotive Engineering magazine / SAE International
Mike LeGault
High-Performance Composites & Composites Technology magazines
Josh Madden
Mold Release Products
Peggy Malnati
Composites Technology magazine & Omnexus.com
Rhoda Miel
Fred Deans, Allied Composite Technologies LLC
Plastics News magazine & Plastics in Lightweight & Electrical Vehicles Conference
Materials
Thomas Moore
Norm Kakarala, Inteva Products
Environmental
Monica Prokopyshen, Chrysler LLC (retired)
Vehicle Engineering Team Award
Anthony Gasbarro, Marubeni America Corp.
Safety
Suzanne Cole, Miller Cole LLC
Hall of Fame
Nippani Rao, Rao & Associates
Past Chair Award
Anthony Gasbarro, Marubeni America Corp.
Process, Assembly & Enabling Technologies
Suresh Shah, Delphi Corp.
Powertrain
Jake Welland, Hyundai-Kia America Technical Center
Grand Award
Jeff Helms, Ticona Engineering Polymers
_____________________________________________________________
9:00-11:00 pm Afterglow Reception
Everyone Invited to Attend
Chrysler LLC (retired)
Allan Murray
Allied Composite Technologies LLC, SPE Emeritus
Matthew Naitove
Plastics Technology magazine & PLASPEC Global Plastics Selector
Irv Poston
General Motors Corp. (retired)
Ron Price
Global Polymer Solutions
Nippani Rao
Rao & Associates
Tom Russell
Allied Composite Technologies LLC
Doug Smock
PlasticsToday.com
Chris Theodore
Ford Motor Co. / Theodore Associates LLC
Mike Tolinski
Plastics Engineering magazine / SPE
William White
Lawrence Technological University
Drew Winter
Special thanks to our student usher sponsor,
Ticona and our student usher organizers,
Jim Keeler and Jackie Rehkopf.
WardsAuto.com
Conrad Zumhagen
The Zumhagen Company LLC
5
WELCOME
to
Gala & Afterglow Sponsor
Silver Sponsor
Advertising Only
Sponsors
Bronze
™
Media / Association
6
the
Gold Sponsors
Sponsors
Sponsors
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2011
SPE
Au t o m o t i v e
B o d y
In n o v a tio n
ABC Group - Exterior Systems
ABC Group - Exterior Systems
Styron LLC Pulse® 2000 EZ PC/ABS / Blow molding
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.
Fender Vent Mold-in-Color Multilayers
Ford Motor Co.
2012 MY Ford® F250®, F350®, F450®, F550® pickups
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Lupini Targhe S.p.A.
Gamma Mold
BASF Corp.
Luran ASA & Chromed ABS
Gamma Mold
This injection-molded ASA and chromed ABS design offered black lettering
inside a chrome bezel while avoiding costly paint-over-chrome and subsequent 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.
10
C o m p e tit io n
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Spoiler with Integrated Antenna & Amplifier
General Motors Co.
2011 MY Chevrolet® Camaro® convertible sports car
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
A w a r d s
Mold-in-Color Ford Oval
Ford Motor Co.
2012 MY Ford® F250® Superduty pickup
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Tribar Manufacturing LLC
Tribar Manufacturing LLC
Evonik Industries / SABIC Innovative Plastics
PMMA & Plating Grade ABS
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 improvements 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 environmental improvement (through elimination of paint), resulting in a direct cost
savings of 35%.
2 0 1 1
SPE
Au t o m o t i v e
Innova ti o n
A w a r d s
B o d y
C o m p e tit io n
ABC Group
Delta Tool
SABIC Innovative Plastics
Geloy® XP4034 ASA+PC /
Gas-counter-pressure injection molding
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.
G a l a
E x t e r i o r
Structural ASA Aero Spoiler
Ford Motor Co.
2012 MY Ford® Edge® & Lincoln® MKT CUVs
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
&
Ram Box Assembly with Lid
Chrysler Group LLC
2012 MY Dodge® Ram® pickup
System Supplier:
Material Processor:
Material Supplier:
Resin / Process: Tooling Supplier:
Penda Corp.
Penda Corp. (lid), Evco Plastics (bin)
River Bend Industries (end caps)
Asahi Kasei Plastics North America Inc. Thermylene® P8-40FG-4611 (box), P6-15FG-0741 (lid);
P6-15FG-0754 (end caps) PP /
Twin-sheet thermoforming
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.
Sealing Stud for Rear Lamp & Appliqué Attachments
General Motors Co.
2012 MY Chevrolet® E10 pickup
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
ATF Inc.
Not Stated
Nylok Corp.
Not Stated
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.
11
2011
SPE
Au t o m o t i v e
B o d y
In n o v a tio n
Leopold Kostal GmbH & Co. KG
Leopold Kostal GmbH & Co. KG
SABIC Innovative Plastics
Cycolac® DL100LG ABS/PC / Injection molding
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.
Seat-Controls Plastic-Module Bracket
Ford Motor Co.
2012 MY Ford® Escape® SUV & Kuga® CUV
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Low-Gloss, Molded-in-Color Steering-Column Cover
BMW AG
2011 MY BMW® 5 Series mid-size luxury sedan
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
A w a r d s
Second-Row Vanity Mirror & Dome Lamp with Dual LED
Ford Motor Co.
2013 MY Lincoln® Town Car® livery
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Daimay NA Automotive, Inc.
Not Stated
Not Stated
PC/ABS
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.
Overmold-Cushion Suspension
Ford Motor Co. 2012 MY Ford® Escape® SUV & Kuga® CUV
Group LLC 2012 MY Dodge® Ram® pickup
System Supplier:
Magna Seating LVSS
Material Processor: Genesis
Material Supplier:
BASF Corp. Resin / Process: Ultramid® A3WG6 PA 6/6 30% GF / Injection molding
Tooling Supplier:
ETCS Inc.
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 molding
Tooling Supplier:
Advanced Mold Engineering 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, eliminating 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.
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 climatecontrol 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.
2 0 1 1
SPE
Au t o m o t i v e
Innova ti o n
A w a r d s
B o d y
Molded-in-Color Air-Register Bezel
Ford Motor Co.
2011 MY Ford® Escape® SUV & Kuga® CUV
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
TRW Engineered Fasteners & Components Fisher Tech
Samsung Chemical
WP-1098 PC/ABS / Multiple
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.
C o m p e tit io n
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TPE “Coating” for Center Finish Panel
Hyundai-Kia Automotive Group
2011 MY Hyundai® Veloster® CUV
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Dongkook Corp.
Hankook Mold Corp.
Kriburg GmbH & Co. KG
TPE HTP8830 / 98
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.
13
2011
SPE
Au t o m o t i v e
In n o v a tio n
A w a r d s
C o m p e tit io n
&
G a l a
C h a s s i s / H a r d w a r e
Below Belt Glass Bracket
Ford Motor Co.
2011 MY Ford® Focus® compact car (globally)
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Brose Fahrzeugteile GmbH & Co. KG
Erwin Quarter, Inc.
RheTech, Inc.
PP T20T100 PP / EPDM
Camoplast Inc.
This multi-shot execution of a below-belt weatherstrip eliminates seal-unzipping 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.
Plastic Racheting-Stud Insert
General Motors Co.
2012 MY Chevrolet® Camaro® sports car
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
ITW Super Products
ITW Shanghai
Mitsubishi Engineering Plastics
Lupital® F20-03 POM / Injection molding
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.
14
Outer Belt Weatherstrip Hidden Fastener Retention
Ford Motor Co.
2011 MY Ford® All Focus® compact cars (globally)
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Henniges Automotive
MANUFACTURAS MAHER II, S.L .
BASF Corp.
Ultramid® PA 6/6 / Injection molding
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.
Composite Underbody Shields
General Motors Co.
2012 MY Chevrolet® Volt® extended range EV
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Grupo Antolin-Irausa, S.A.
Grupo Antolin-Irausa, S.A.
Quadrant Plastic Composites
SymaLITE® LWRT PP+GF / Compression molding
Not Stated
These ultra-lightweight composite underbody shields are used to improve
aerdynamics for lower fuel consumption and to protect the vehicle’s undercarriage 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.
2 0 1 1
SPE
Au t o m o t i v e
Innova ti o n
A w a r d s
C o m p e tit io n
&
G a l a
C h a s s i s / H a r d w a r e
B-Pillar Appliqué
Ford Motor Co.
2011 MY Ford® Focus® compact car
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Windsor Mold Group
Windsor Mold Group
Evonik Industries
Acyrlite® ABS with PMMA overmold
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 & Shaft
Ford Motor Co.
2011 MY Ford® All Focus® compact cars (globally)
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Brose Fahrzeugteile GmbH & Co. KG
Mitsuba Corp.
DuPont Automotive
Hytrel® TPC-ET polyester / Injection molding
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 accommodating drum spline was critical to the customer. The application saved $450,000
USD direct and $250,000 USD indirect cost savings annually.
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GM Retiree, Dave Reed Named SPE® Automotive Lifetime
Achievement Winner for Auto Plastics Contributions
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 responsibility 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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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 assistance, 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.
C o m p e t i t i o n
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2011
SPE
Au t o m o t i v e
In n o v a tio n
A w a r d s
C o m p e tit io n
&
G a l a
M a t e r i a l s
Low-Cost Automated Preform Fabric Assembly
Jiangsu Xinri E-Vehicle Co. Ltd.
2011 MY XR-EV05 electric delivery vehicle
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Advanced Fiber Materials Technologies Co.
Advanced Fiber Materials Technologies Co.
Owens Corning
Araldite® Low-Viscosity LY 564 Epoxy
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.
EP Biobased Polyester Polymer
Toyota Motor Co.
2011 MY Toyota® Prius® “A” Alpha station wagon
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Kojima Press Industry Co., Ltd. Howa Plastics Co., Ltd.
DuPont Automotive
Sorona® EP 2045 PTT / Not stated
Not Stated
This is the first use of polytrimethylene terephthalate (PTT), an entirely new
thermoplastic polyster, which also happens to be biobased. This high-temperature 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.
22
Transmission Components in Fluoroelastomers
General Motors Co. 2011 MY All GM Vehicles using 6L45,
6L50, 6L80, & 6L90 transmissions
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Robert Bosch LLC
Freudenberg-NOK
Freudenberg-NOK
FluoroXprene® B FKM & ETFE / Injection molding
Freudenberg-NOK
Replacing both injection molded PA and conventional rubber, a new multipatented 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.
2011
SPE
Au t o m o t i v e
In n o v a tio n
M a t e r i a l s
Anti-Stain Finish for Cloth Seats
Hyundia-Kia Automotive Group
2011 MY Hyundai® Soul® CUV & Kia® Optima® mid-size sedan
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Kolon Glotech, Inc.
Kolon Glotech, Inc.
Kolon Glotech, Inc.
Cleantex® Innoclean® Polyester
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%.
Volcanic-Filler Pillar Trim
Hyundai-Kia Automotive Group 2011 MY Kia® Pride® subcompact &
Kia®Optima® mid-size sedan and Hyundai® Elantra® compact car
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Plakor Co. Ltd.
Plakor Co. Ltd.
Hyundai EP Co. Ltd.
Supol® HL345CL PP / Injection molding
Not Stated
This lightweight, injection-molded PP pillar trim provides the texture and appearance of more costly fabric-wrapped trim through use of a unique filler combination 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 Bracket
General Motors Co.
2010 MY Chevrolet® Equinox® CUV
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Magna International Inc.
Magna International Inc.
Asahi Kasei Plastics North America Inc.
Thermylene® P7-60FG-0790 BK711 PP
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 Spill
General Motors Co.
2011 MY Chevrolet® Volt® extended-range EV
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
GDC Inc.
Not Stated
Mobile Fluid Recovery, Inc.
Enduraprene® 2395 PP/PE/SBR / Multiple
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% postconsumer PE bottles.
Renewably Sourced PA for Biodiesel Fuel Lines
Fiat S.p.A.
2011 MY Fiat® Diesel engines, various models
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Hutchinson
Hutchinson
DuPont Automotive
Zytel® RS 1610 PA 10/10 / Extrusion
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.
30
Loadfloor Using Coconut Felt
Ford Motor Co.
2012 MY Ford® Focus® BEV
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Autoneum Holding AG
Aftech LL & Hobbs Bonded Fibers
Natural Composites, LLC
PP / Not Stated
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 Hydrographics
Chrysler Group LLC
2011 MY Chrysler® 300 luxury sedan
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
CpK Interior Products
Dongguan Taica Hirosawa Technologies Co., Ltd. &
Hirosawa Automotive Trim
Taica Corp.
PC/ABS / Injection-molded substrate
& hydrographics coating
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.
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Bio-Polyurethane Foam in Automotive Seating Head Restraints
Ford Motor Co.
2011 MY Ford® Fusion® & Lincoln® MKZ® sedans
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Lear Corp.
Lear Corp.
Lear Corp.
Bio-Based PUR
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 Panels
Ford Motor Co.
2012 MY Ford® Focus® compact car
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Automotive Component Holdings LLC
Automotive Component Holdings LLC
BASF Corp.
Elastofoam® Balance 27730 & 27731 PUR Foam /
Foam in place
Not Stated
The use of bio-based castor beans for the polyurethane foam in this application 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.
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Chrysler Group LLC Wins 2011 Vehicle Engineering Team
Award from SPE® Automotive Division
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, engineering, 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 nickelshell tool technology—were used.
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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.
is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their owners.
® SPE
® Chrysler 200 and Dodge Avenger are registered trademarks of Chrysler Group LLC.
photo credit: Chrysler Group LLC
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Reinforced Airbag Lid in Foam (RALF)
Ford Motor Co.
2011 MY Ford® Focus® compact car
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Faurecia Interior Systems
Faurecia Interior Systems
Not Stated
PET & PUR / Not Stated
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 foamin-place airbag construction and is cost-neutral.
36
Crash-Boxes for Truck-Cabin Occupant Protection
Volvo-Eicher Commercial Vehicle Pvt Ltd.
2011 MY India 7T LCV commercial truck
System Supplier: Machino Plastics Ltd.
Material Processor: Machino Plastics Ltd.
Material Supplier: SABIC Innovative Plastics
Resin: Xenoy® 1102 PC/PBT
Tooling 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,
2011
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Undertray with Pedestrian-Safety Functionality
Ford Motor Co.
2011 MY Ford® C-Max® world car
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Faurecia
Faurecia
SABIC Innovative Plastics
Xenoy® iQ1103R PC/PBT / Injection molding
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.
38
Pedestrian-Safety Upper Load Path
Land Rover
2011 MY Range Rover® Evoque® CUV
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Magna International Inc.
Magna International Inc.
SABIC Innovative Plastics
Xenoy® iQ1103R PC/PBT / Injection molding
Not stated
This 1-piece injection-molded fascia reinforcement eliminates the need for
support brackets and offers tuned stiffness to control lower-leg kinematics 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.
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SuperPlug® Door Hardware Module is 2011 Hall of Fame
Winner at SPE® Auto Innovation Awards Competition
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 previously 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
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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 investment 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-absorbing 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.
is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their owners.
® SPE
Venture and Malibu, Pontiac Transport, Oldsmobile Silhouette and Cutlass, and Opel Sintra are registered trademarks of General Motors Co.
® Chevrolet
SuperPlug is a registered trademark of Inteva Products, LLC.
®* Xenoy
is a trademark of SABIC Innovative Plastics IP B.V.
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Composite Wheel Weights
General Motors Co.
2011 MY Cadillac® CTS sedan & Corvette® sports car
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
ESYS Automation
3M
3M
3M proprietary / Extrusion
ESYS Automation
This innovation uses extrusion of a highly filled polymer and automation 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, application cycles, and an average of 0.3-0.5 grams of excess weight per wheel.
Advanced Material Characterization for Interior Parts
Ford Motor Co.
2012 MY Ford® Explorer® SUV
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Not Stated
Not Stated
Not Stated
Not Stated
Not Stated
Use of advanced materials characterization of plastics enables improved analytical 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.
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Integrated Liftgate Trim Grab Handle
Ford Motor Co.
2012 MY Ford® Focus® compact hatchback
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
NYX Inc.
NYX Inc.
Not Stated
PP / Injection molding
Aalbers Tool
Through design and tooling innovations, the injection-molded polypropylene
liftgate grab handle was molded in a single piece vs. previous 2-piece assemblies thanks to 3 large cavity-side slides in the tool. The innovation saved 0.1
lb and $0.60 USD / vehicle.
1-Piece Structural TPO Aero Rocker Molding
Ford Motor Co.
2012 MY Ford® Edge® SUV
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
ABC Group
ABC Group
LyondellBasell Advanced Polyolefins USA, Inc.
Sequel® TYC 852P TPO
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.
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MuCell® Instrument Panel
Ford Motor Co.
2012 MY Ford® Escape® compact SUV & Kuga® compact CUV
System Supplier:
Faurecia
Material Processor: Faurecia
Material Supplier:
SABIC Innovative Plastics & Flint Hills Resources
Resin / Process: Stamax® EXRP-49 30YK270 & AP3335-HF long glass /
10% reactor-grade talc-filled PP /
Microcellular injection molding
Tooling 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.
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Plastic Transmission Accumulator Piston
Chrysler Group LLC
2012 MY All Chrysler Vehicles with Automatic Transmissions
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Chrysler Group LLC
Freudenberg-NOK Sealing Technologies
Chevron-Phillips Chemical Co. LLC
Ryton® R-Y-120 PPS / Injection molding
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 philosophy 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.
Ni-MH Battery Package for HEV
Volkswagen AG
2010 MY Volkswagen® Touareg® hybrid CUV
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
Sanyo Electric
Not Stated
SABIC Innovative Plastics
Noryl® SE100P M-PPE / Injection molding
Not Stated
Injection molded modified-PPE resin was used for this compact Ni-MH
battery module package, providing greater dimensional accuracy than glassreinforced 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.
Battery Pack
General Motors Co.
2011 MY Chevrolet® Volt® extended-range EV
System Supplier:
Material Processor: Material Supplier:
Resin / Process: Tooling Supplier:
General Motors Co.
MANN+HUMMEL GmbH
BASF Corp.
Ultramid® 1503-2F PA 6/6 33% GF, HS /
Injection molding
Omega Corp.
Thermoplastic battery frames are an integral part of electric-vehicle thermal
management, channeling coolant to and from the cells. The use of injectionmolded hydrolysis-resistant PA 6/6 for thermal-cycling management is a
lightweight enabling material for this design, which required exacting manufacturing consistency and high levels of repeatability and reproducibility.
45
2 0 1 1
SPE
Au t o m o t i v e
Innova ti o n
A w a r d s
C o m p e tit io n
&
G a l a
P o w e r t r a i n
Plastic Oil Strainer
Hyundai-Kia Automotive Group
2011 MY Hyundai® i10® subcompact
System Supplier:
Material Processor: Material Supplier:
Resin: Tooling Supplier:
Sambo Motors
Taeyoung Chemical
Desco
Glass-Filled PA 6/6
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.
47
The Hall of Fame Award is given annually for
an application that has been in continuous use
for 15 years or more, and has made a signficant
and lasting contribution to the application of
HALL OF FAME By Year
48
plastics in automobiles.
Year
Recognized
OEM
Application
Material
2010
General Motors Co. Front & Rear TPO Bumper Fascias
TPO
2009
General Motors Co.
Thermoplastic Vertical Body Panel
MPPE/PA
2008
Chrysler LLC
Rear Seat Cushion
PUR Foam
2007
Ford Motor Co.
Radiator End Tank PA 6/6
2006 General Motors Corp. Thermoplastic Front Grille ABS
2005
Porsche
Thermoplastic Intake Manifold
PA
2004 Ford Motor Co. Box Beam Bumper PC/PBT
2003
General Motors Corp.
Dual-Density Energy Absorbing Bumper System
PP
2002
General Motors Corp.
Mini-Wedge Latch and Door-Lock Actuator
PA
2002 General Motors Corp.
Wiper-System Transmission Housing
PA
2001
General Motors Corp.
Instrument-Panel Retainer
SMA
2000
Volkswagon AG
Fuel Tank
HDPE
1999 Ford Motor Co.
Hydraulic Clutch Actuator
PA
1998
Citroën
Fan Shroud
PA
1997
Ford Motor Co.
Transmission Seal
PPS
1996
General Motors Corp.
Front Fenders
RIM-PUR
1995
General Motors Corp.
Guide-Flex Energy Absorbers
EVA
1994
Ford Motor Co.
Headlamp Assembly
PC
1993
General Motors Corp.
Front/Rear Bumper Covers
RIM-PUR
1992
General Motors Corp.
Composite Exterior Body Panels
SMC
1991
General Motors Corp.
Tilt Steering-Wheel Centering Sphere
Acetal
1990
General Motors Corp.
Transverse Leaf Spring
Epoxy
1989
American Motors Corp.
Battery Case
PP
1988
Ford Motor Co.
Windshield Interlayer
PVB
1987
General Motors Corp.
Grill-Opening Panel
SMC
1986
Chrysler Corp.
Heater Housing
PP
1985
Chrysler Corp.
Disc-Brake Piston
Phenolic
1984 General Motors Corp.
Front-Fender Wheel Liner
PP
1983
General Motors Corp.
Emissions Control Canister
PA
GRAND AWARD WINNER By Year
50
Year
OEM
APPLICATION
MATERIAL
2010
Ford Motor Co.
Diesel-Exhaust Fluid (DEF) System
Multiple
2009
General Motors Co.
Shielded Plastic Case Radio
PC/ABS
2008
BMW
Twin-Sheet Blow-Molded Fuel System
HDPE
2007
General Motors Corp. Backlighting with Color-Converting Plastic
PC
2006 DaimlerChrysler Blow-Molded Front- & Rear-Bumper System
TPO
2005
Honda Motor Co.
Composite In-Bed Trunk
SMC
2004 Ford Motor Co.
Door Trim with Integrated Acoustic Chamber and Subwoofer PP 2003
DaimlerChrysler
Roof Module
PC Copolymer
2002
DaimlerChrysler
Extruded Polymer Film Fascia
Multi-Layer Ionomer
2001
General Motors Corp.
Nanocomposite TPO
Nanocomposite TPO
2000
Ford Motor Co.
Controlled Energy Management Bumper Isolator
HDPE
1999
DaimlerChrysler
Fan Shroud and Reservoir Assembly
PP
1998
Mitsubishi Motors
“I” Section Bumper Beam
PP-GMT
1997
Ford Motor Co.
“Carpet to Car Parts”
PA
1996
General Motors Corp.
Structural Battery Tray
PP-GMT
1995
Ford Motor Co.
Integrated Front-End System
SMC
1994
General Motors Corp.
Thermoplastic Air-Intake Manifold
PA Copolymer
1993
Ford Motor Co.
Front-Suspension Stabilizer Link
POM
1992
Chrysler Corp.
Instrument-Panel System
PP-GMT, MPPE, PP & PU Foam
1991
Chrysler Corp.
Integrated Child’s Seat and Top Impact Pad
PP-GMT, Expanded MPPE
1990
General Motors Corp.
Exterior Door Panel
PC/ABS
1989
Chrysler Corp.
Composite Wheel
SMC/XMC
1988
General Motors Corp.
Front Fender
MPPE/PA
1987
General Motors Corp.
Quarter-Panel Assembly – Sportside
SMC
1986
General Motors Corp.
Quarter Window
PMMA
1985
General Motors Corp.
Windshield with Anti-Lacerative Layer
Polyvinyl Butyral/PE Film
1984
Ford Motor Co.
Drive Shaft
Vinylester/Graphite/Glass
1983
General Motors Corp.
Exterior Body Panels
SMC, RIM, RRIM, & TPO
1982
General Motors Corp.
Tailgate Assembly
SMC
1981
Ford Motor Co.
Radiator-Core End Caps
PA
1980
General Motors Corp.
Rear-Axle Leaf Spring
Epoxy
1979
Ford Motor Co.
Grille-Opening Panel Assembly
SMC
1978
General Motors Corp.
Bucket-Seat Frame
SMC
1977
Ford Motor Co.
Instrument Panel
1976
Ford Motor Co.
Fender Aprons
PP
1975
American Motors Corp.
One-Piece Jeep Top
PC
1974
General Motors Corp. Fascia and Rear Bumper Cover
RIM-PUR
1973
Ford Motor Co.
Block-Heater Motor Housing
1972
General Motors Corp.
Radiator Fan-Shroud Assembly
PP
1971
Ford Motor Co.
Transmission Reactor
Phenolic
2 0 1 1 SPE Au 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
Plaque & trophy
Order
Form
C ategory W inners
Full-Size Trophy (5x7 in.) Quantity _____ @ $225. ea
Category ________________ Application _______________
Replica Trophy (3x5 in.)
Category ________________ Application _______________
Quantity _____ @ $145. ea
C ategory F inalists
Acrylic Desk Plaque
Quantity _____ @ $130. ea
Category ________________ Application _______________
N omination D isplay P laques (available for ALL nominated parts)
9x12 in.
Quantity _____ @ $16. ea
Category ________________ Application _______________
Note: Prices do not include shipping. You will be contacted after your order is received to confirm the application, quantity, and shipping costs.
Name: ____________________________________________________________________________
Company: ______________________________________ Division: _________________________
Company Address: _________________________________________________________________
City/State or Province/Postal Code: __________________________________________________
Phone: ____________________________________ Fax: __________________________________
Email: ____________________________________________________________________________
Signature: ________________________________________________________________________
o Bill my credit card o Invoice me at the address above
Total Amount Due: $ ________________
Credit Card Type: _________________ Credit Card Number: _______________________________
(Visa, MC, AMEX accepted)
Name on Card: ________________________________________ Expiration Date: ___________
Fax orders to +1.248.244.8925
All orders due by December 31, 2011
Questions: please send an e-mail to [email protected]
51
Society of Plastics Engineers
Automotive Division
Di 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
CHAIR
Anthony Gasbarro
Marubeni USA
PAST-CHAIR
Jeffrey Helms
Ticona Engineering Polymers
DIVISION COUNCILOR
Tom Pickett
General Motors Co.
CHAIR-ELECT
Jeffrey Helms
Ticona Engineering Polymers
TREASURER
Jackie Rehkopf
Plasan Carbon Composites
DIRECTORS EMERITUS
Josh Madden
Materials Engineering Services
VICE-CHAIR
Yvonne Bankowski
Ford Motor Co.
SECRETARY
Monica Prokopyshen
Chrysler LLC (Retired)
Allan Murray
Allied Composite Technologies LLC
Nippani Rao
Chrysler LLC (Retired)
Committee Chairpersons
INNOVATION AWARDS PROGRAM
Jeffrey Helms
Ticona Engineering Polymers
NEWSLETTER EDITOR
Kevin Pageau
Tegrant Corp.
SOCIAL Suzanne Cole
Miller Cole LLC
ANTEC TPC
Anthony Gasbarro
Marubeni USA
NEWSLETTER SPONSORSHIP
Teri Chouinard
Intuit Group, LLC
Brian Grosser
Samsung
AutoEPCON
Norm Kakarala
Inteva Products
GOLF OUTING
Fred Deans
Allied Composite Technologies
MEMBERSHIP
Bill Pippine
Takata Holdings LLC
INTER SOCIETY
Jackie Rehkopf
Plasan Carbon Composites
ACCE, COMMUNICATIONS & WEB
Peggy Malnati
Malnati & Associates
EDUCATION
Monica Prokopyshen
Chrysler LLC (Retired)
B o a r d o f Di r e c t o r s
52
TO MAY 2014
TO MAY 2013
TO MAY 2012
Bonnie Bennyhoff
ExxonMobil
Chemical
Chuck Jarrett
SABIC Innovative
Plastics
Fred Deans
Allied Composite
Technologies
Peggy Malnati
Malnati &
Associates
Ed Garnham
General Motors
(retired)
Jay Raisoni
Adell Plastics
Jane Aselage
Ford Motor Co.
Sheldon Brown
Toyota Motors
Ron Price
Global Polymer
Solutions
Suzanne Cole
Miller Cole LLC
Dave Reed
David Reed
Consulting LLC
Mike Masserant
Ford Motor Co.
Mike Whitens
Ford Motor Co.
Brian Grosser
Samsung
Nippani Rao
Rao Associates
Norm Kakarala
Inteva Products
Jackie Rehkopf
Plasan Carbon
Composites
Mark Lapain
Magna
International
Kevin Pageau
Tegrant Corp.
Suresh Shah
Delphi Corp.
Salute
to our Sponsors
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.
media / association sponsors
Automotive 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
Gala & Afterglow Sponsor
Ticona Engineering Polymers
GOLD SponsorS
American Chemistry Council – Plastics Division
DuPont Automotive
Faurecia Interior Systems
ExxonMobil Chemical Co.
SILVER SponsorS
Advanced Composites
BRONZE SponsoRS
AsahiKasei 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
SponsoRS
Adell Plastics Inc.
Brose Fahrzeugteile GmbH & Co. KG
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