27
Oct
16

Materials Category Finalists Announced for 2016 #SPEInnovationAwards Competition

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The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Materials Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: MATERIALS

NVH Baffles

OEM Make & Model: 2016 Ford Motor Co. Ford F-150 pickup

Tier Supplier/Processor: Henkel AG & Co. KGaA / Henkel AG & Co. KGaA & Wittmann Battenfeld, Inc.

Material Supplier / Toolmaker: Henkel AG & Co. KGaA / Creative Die Mold Corp.

Material / Process:  EcoLon GF1960 PA 6/6 (100% post-consumer recyclate (PCR)) & ethylene vinyl acetate (EVA) / injection molding

Description:  Because aluminum body panels expand at twice the rate that steel ones do, a new baffle sealing package was needed that would maintain adhesion to the substrate during thermal expansion of the aluminum. It also needed to reduce or eliminate noise/vibration/harshness (NVH) throughout the vehicle to improve driver comfort through a quieter interior. A EVA expandable sealer with a blowing agent that activates during e-coat and produces an innovative elastic cross-linking network was developed to improve hot-tear strength and elongation vs. previous materials. The EVA foam is injection overmolded onto a PA substrate.

Rhapsody Blue MIC Vehicle Environment

OEM Make & Model: 2016 Ford Motor Co. Lincoln Continental luxury sedan r

Tier Supplier/Processor: Americhem Inc. / Multiple

Material Supplier / Toolmaker: Americhem Inc. & Multiple / Multiple

Material / Process: Multiple PP, TPO, ABS, PA, POM / Multiple

Description:  Project goals were to achieve a unique MIC color space that looks luxurious but appeals to today’s generation. It involved using the first transparent pigment-based interior color deliverable across 76 base resins for the vehicle interior. Once the color was mastered, early attempts showed it was prone to metamerism with a red/green directional hue shift. Numerous attempts to achieve color consistency bidirectionally with standard pigment adjustments did not solve the problem. Finally, the color was remastered using a non-titanium dioxide (TIO2) system that did not exhibit hue shift, eliminating the need to paint and creating a calming, cool color environment.

Vacuum Brake Tubes

OEM Make & Model: 2016 General Motors Co. Chevrolet Silverado & GMC Sierra pickups

Tier Supplier/Processor: Cooper Standard

Material Supplier / Toolmaker:  DSM Engineering Plastics / Not stated

Material / Process:  Arnitel CM622 thermoplastic polyester elastomer (TPC-ET) /Not stated

Description: A high-performance thermoplastic was needed for vacuum brake tubing to replace reinforced rubber. It needed broad temperature performance (-40-150C), chemical resistance, burst strength to 60 bar minimum and flexural strength to 50 N minimum. It also had to resist vacuum collapse after 2 hr @ 150C and provide impact retention after 336 hr @ 150C. The design was changed to use a smaller diameter, thinner wall to simplify engine / undercarriage routing and eliminate heat shields plus allow quick connects. A TPC-ET elastomer with high thermal oxidative stability was developed. It is 30% lighter, less costly, and eliminates brackets.

Lightweight TPO Bumper Cover

OEM Make & Model: 2017 Hyundai Motor Group Hyundai Genesis G90 luxury sedan

Tier Supplier/Processor: ECO Plastic

Material Supplier / Toolmaker:  Hanwha Total Petrochemicals Co., Ltd. / Hyundai Motor Group

Material / Process:  NB71 TPO / injection molding

Description:  A new, lighter weight TPO bumper cover was developed using high-crystallinity PP, ethylene-octane rubber, and a combination of nano-size talc and micron-size whisker fillers similar to magnesium oxysulfate.  The material provides high mechanical performance, improved dimensional stability, and low coefficient of linear thermal expansion (CLTE) thanks to the high aspect ratio filler. Weight is reduced 7-10% and the material is cost neutral vs. the material it replaced. Additionally, 6 patents have been obtained on the development.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

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