Archive for the 'Upcoming Events' Category

15
Nov
16

Closed-Loop Recycling of Bottles was Environmental Category Winner @ 46th #SPEInnovationAwards

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The Closed-Loop Recycling of Bottles on the 2016 Chevrolet Equinox CUV and GMC Terrain SUV from General Motors Co. was the Environmental Category winner in the 46th-annual SPE® Automotive Innovation Awards Competition. System supplier, Exo-S, material processor, Rogers Foam Co., and materials suppliers, Wm. T. Burnett & Co. and Palmetto Synthetics LLC also were named on the award.

ev-closed-loop-recycling-of-bottles

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

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

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12
Nov
16

Structural Front End Module with Active Grille Shutter was Body Exterior Category Winner @ 46th #SPEInnovationAwards

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The Structural Front End Module with Active Grille Shutter on the 2016 Ford Super Duty pickup from Ford Motor Co. was the Body Exterior Category winner in the 46th-annual SPE® Automotive Innovation Awards Competition. System supplier and material processor, Shape Corp. and material supplier, Celanese Corp. also were named on the award.

be-structural-front-end-module-with-active-grille-shutter

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

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

30
Oct
16

Safety Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Safety 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: SAFETY

Seat Cushion Frame and Storage Door

OEM Make & Model: 2016 Ford Motor Co. Ford Super Duty pickup

Tier Supplier/Processor: Royal Technologies Corp.

Material Supplier / Toolmaker: Celanese Corp. / Vortec Tooling Solutions, Inc.

Material / Process:  Celstran GF40-20 LFT-PP / injection molding

Description:  For the first time, a polymer composite has replaced magnesium in a structural seat-cushion frame and under-seat storage lid for a front center 20% seat with integrated restraint system. The application is weight neutral and lower cost (≈$4 USD/unit), and satisfies all safety and crashworthiness requirements. Its flexible architecture allows for updates with future enhancements. Injection molded 40% LFT-PP is used to mold the frame, which also features an expanded polypropylene (EPP) antisubmarine foam block and a lockable ergo-latch. The assembly represents a significant reduction in carbon footprint vs. magnesium and has yielded 2 awarded and 2 pending patents.

Next Generation Armrest for Side Impact

OEM Make & Model: 2016 Ford Motor Co. Ford Super Duty pickup

Tier Supplier/Processor:  Yanfeng USA Automotive Trim Systems Company, Inc.

Material Supplier / Toolmaker: LyondellBasell / ToolPlas Systems Inc.

Material / Process:  SG702  PP & multiple / injection molding

Description:  Minimizing door intrusion during side impacts usually requires intensive body-structure countermeasures. Abdomen criteria for 5th and 50th percentile dummies are primarily driven by door-trim armrest stiffness during side impacts. This new door-trim armrest improves safety as a tuning component by acting as a load limiter and absorbing energy. Comprised of a skin, foam pad, PP-nonwoven trampoline fabric, ABS armrest substrate, and PP trampoline frame, the system is significantly softer than previous designs, substantially outperforming static and dynamic functional requirements without adding countermeasures, cost, or weight. Further, armrest durability improves 6 times, and costs and weight are reduced $31.80 and 3.8 kg per vehicle.

Modular Composite Front-Seat Cushion Pan

OEM Make & Model: 2017 Ford Motor Co. Lincoln Continental luxury sedan

Tier Supplier/Processor: Leggett & Platt, Great Lakes Trim & Grammer Industries / Engineered Plastics, Grand Traverse Plastics & Johnson Electric

Material Supplier / Toolmaker: BASF Corp., Advanced Composites, Inc. & DuPont Automotive / MacLean-Fog, Commercial Tool & Die & Johnson Electric

Material / Process:  ULTRAMID B3ZG7 OSI PA, ADX 5017 TPO, Delrin 100P NC010 POM / injection molding

Description:  This patent-pending, plastics-intensive, modular composite front seat-cushion pan (in impact-modified 35% GR PA), side-airbag deployment back panel (in talc-filled TPO), and power head-restraint drive nut (in POM) create a robust and dynamic crash-energy management system for front impact protection, side airbag deployment, and energy management for occupant impact protection. Further, the system enables modular assembly and scalable features for assembly ease.  Already 83 patents have been filed and 12 granted on this innovative seat system.

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

29
Oct
16

Process, Assembly & Enabling Technologies Category Finalists Announced for 2016 #SPEInnovationAwards Competition

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The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Process, Assembly & Enabling Technologies 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: PROCESS, ASSEMBLY & ENABLING TECHNOLOGIES

Zipper Clip

OEM Make & Model: 2017 General Motors Co. Chevrolet Malibu midsize sedan

Tier Supplier/Processor: 3 Dimensional Services Group

Material Supplier / Toolmaker: Celanese Corp. / 3 Dimensional Services Group

Material / Process:  Celcon M90 POM / injection molding

Description: The zipper clip is a plastic solution that gives the holding benefits of a stud-and-nut combination while reducing production limitations. Ideal for use where a nut is desired but not feasible, this is the first stud insert with 4 ratcheting control features and a self-centering 2-way locator that holds over 120 lb/54.43 kg of weight while it requires low ergonomic effort (5.11 lb/2.32 kg) for assembly. The design reduces spring back as well as weight and cost and eliminates the need for assembly equipment as well as an isolator, since it protects the stud from corrosion.

Hot-Gas Welded Thermostat Housing Assembly

OEM Make & Model: 2017 Ford Motor Co. 3.5L V6 Cyclone TiVCT GTDI engines

Tier Supplier/Processor: Plastic Tec – Bocar Group

Material Supplier / Toolmaker: DuPont Automotive / Schweiger GmbH & Co. KG

Material / Process:  Zytel HTN HTN51G35HSLR BK420 PPA / injection molding & hot gas welding

Description:   Hot-gas welding joins both halves of this 35% GR-PPA thermostat housing assembly. The part has a small welding-flange footprint but high weld strength because there is no fiber/material degradation during the joining process. In fact, it is the only welding process that permits bridging of glass across the joint. The weld distance is held within 0.1 mm, enabling parts to package into very limited spaces with tight tolerances. Since the part is not touched during welding, there is no sticking. Versus previous aluminum solutions, the PPA assembly is 30% lighter and 40% less costly.

Two-Shot Map Lamp Lens

OEM Make & Model: 2017 Ford Motor Co. Lincoln Continental luxury sedan

Tier Supplier/Processor:  Flex Auto (Flextronics)

Material Supplier / Toolmaker: SABIC / Flex Auto (Flextronics)

Material / Process:  Lexan 143R HFD1830 PC / 2-shot injection molding

Description:  A redesigned capacitive touch lens produced via 2-shot molding eliminates molding defects while maintaining an ideal bonding surface and clear aperture for best light intensity. Eliminating a second tool, the Fresnel pattern is molded into the core of the first shot, which becomes the cavity of the second shot as the latter is layered over the former, keeping both outer surfaces smooth. Using 2 grades of PC with a 40o difference in heat-deflection temperature (HDT) eliminates the problem of the second shot melting the first during overmolding. Eliminating a tool reduced costs 25%.

Robotic Laser Cutting and Welding of TPO Fascia

OEM Make & Model: 2017 General Motors Co. Chevrolet Camaro ZL1 sports car

Tier Supplier/Processor: Magna Exteriors, Inc. / Magna Exterior – DexSys

Material Supplier / Toolmaker: LyondellBasell / Jenoptik AG

Material / Process:  Hifax TYC1168X TPO / injection molding

Description:  A hydraulic punch and sonic welding operation was replaced by robotic laser cutting and welding of a Class A exterior fascia. Unlike other welding processes, it is not necessary to thicken wallstock in weld areas to prevent readthrough with robotic laser welding of brackets on the backside of the part, and that reduces weight slightly. It also eliminates the need for contoured horns and punches. Clean cuts can be made in 1 sec on the painted side of the part. The dual-function process provides greater flexibility between programs and reduces floor space and tooling costs.

Assisted Positive-Locking Junction Box

OEM Make & Model: 2016 General Motors Co. Chevrolet Camaro sports cars

Tier Supplier/Processor: Yazaki North America Inc.

Material Supplier / Toolmaker: DuPont Automotive / Yazaki North America Inc.

Material / Process:  Multiple / Multiple

Description:  This tool-less, single-lever, self-locking underhood bussed electrical center (UBEC) guarantees proper connections for 4 connectors from 4 different wire harnesses using 1 hand and low assembly effort. There is no need to re-orient the UBEC to install mating connectors during OEM assembly. The result is a robust, high-circuit-capacity design that s ergonomically friendly to assembly-line workers. Additional benefits are a 7% weight savings, 8% additional spare electrical content, 10% reduction in overall footprint, better water-ingress protection, and 30% less assembly time.

 

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 .

# # # # #

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

28
Oct
16

Powertrain Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Powertrain 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: POWERTRAIN

Air Intake Manifold

OEM Make & Model: 2015 Volkswagen AG EA21 1.6L engines

Tier Supplier/Processor: Hua Tao Ltd.

Material Supplier / Toolmaker: SABIC / Not stated

Material / Process: SABIC G3135X PP / injection molding

Description:  This is the first air-intake manifold launched in China using 35% GR-PP to replace PA 6/6. The application provides 25-30% cost reduction and 15-20% molded-part weight reduction while retaining properties at high temperatures and improving weld strength, andNVH levels by 5 dB. Unique technology involving finer glass fibers and special sizing helps meet performance requirements. Parts are vibration welded.

Active Fuel-Management System

OEM Make & Model: 2012 General Motors Co. 5.3L V8 LH6 engines

Tier Supplier/Processor: Eaton Corp. Plc. / ITW Global Automotive

Material Supplier / Toolmaker: SABIC / Not stated

Material / Process:  Ultem 2310 polyetherimide (PEI) / injection molding

Description:  To boost fuel efficiency and reduce emissions on classic small-block pushrod V8 engines, an inexpensive and simple technology called active fuel management (displacement on demand) was developed. The efficient and precise electro-mechanical hydraulic system deactivates cylinder valves when power is not needed, then reactivates them when power is called for again. An important component of the system’s solenoid control valves is injection molded from 30% GR-PEI. The material is used for its high stiffness, creep resistance, thermal and chemical resistance, high knitline strength, and ability to be ultrasonically welded. The system improves fuel efficiency 5.5-7.5% and reduces cost 30% vs. metal.

2.0L GTDI Turbo Compressor Outlet Duct

OEM Make & Model:  2017 FCA Alpha Romeo Giulia luxury sedan

Tier Supplier/Processor: ABC Group, Inc.

Material Supplier / Toolmaker:  BASF Corp. / ABC Group, Inc.

Material / Process:  Ultramid Endure D5G3 BM PA 6/6 / 3D flashless blow molding

Description:  To meet more stringent fuel efficiency and tailpipe emissions requirements, engines increasingly are being downsized and turbocharged, but that raises temperatures and pressures that underhood components see during operation. For example, charge air ducts, which take air from the turbocharger to the throttle body, can see continuous-use temps as high as 220C and pressures as high as 207 KPa. Further, compact packaging space requires efficient designs. Switching to a heat-stabilized PA 6/6 capable of being 3D flashless blow molded reduced mass 30-40% and cost 20-25% vs. metallic designs.

 

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 .

# # # # #

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

27
Oct
16

Materials Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

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 .

# # # # #

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

26
Oct
16

Environmental Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Environmental 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: ENVIRONMENTAL

Electronic Power-Steering Pulley

OEM Make & Model: 2017 General Motors Co. GMC Acadia sport-utility vehicle (SUV)

Tier Supplier/Processor: Nexteer Automotive / PRISM Plastics

Material Supplier / Toolmaker: DSM Engineering Plastics / Not stated

Material / Process:  Stanyl TW241F12 PA 4/6 / injection molding

Description:  Project goals were to find ways to reduce cost without reducing performance of the electric power-steering gear-assist mechanism by replacing a powdered metal pulley with an injection molded plastic one. A high-flow grade of 60% GR-PA 4/6 that produces a resin-rich surface for improved belt wear was selected. It offers significant cost savings and reduces mass over 50% vs. the metal pulley. Its assembly method eliminates 3 bolts, which are replaced by a retaining ring. The molded torque tooth provides secure orientation and excellent load-carrying capabilities.

Closed-Loop Recycling of Bottles

OEM Make & Model: 2016 General Motors Co. (GM) Chevrolet Equinox & GMC Terrain cross-over utility vehicles (CUVs)

Tier Supplier/Processor: Exo-s / Rogers Foam Co.

Material Supplier / Toolmaker: Wm. T. Burnett & Co. / Not stated

Material / Process:  Nonwoven from recycled polyethylene terephthalate (PET) / Multiple

Description:  This innovative, multi-stakeholder, cost-neutral recycling project protects the environment, grows local economies, creates jobs, and helps people in a sustainable manner. Water bottles collected at GM operations and from the Flint, Michigan, U.S.A. area are directed into a supply chain that recycles the material into nonwoven fleece for specific applications including engine manifold cover insulation, insulation for coats that convert to sleeping bags for the homeless and are made by formerly homeless women as part of a jobs program, and air filters that purify the air at numerous GM and other manufacturing operations. Already 3.5-million water bottles have been repurposed.

Biomass-based Polyester Blend

OEM Make & Model: 2015 Hyundai Motor Group IONIQ EV

Tier Supplier/Processor: Seoyon E-Hwa Interior Systems Manufacturing

Material Supplier / Toolmaker: SK Chemicals / Not stated

Material / Process:  Skytra bio polyester (PETG/ABS) / Not stated

Description:  The goals of this project were to develop a high-biomass-content thermoplastic polyester blend for window panels and steering-wheel bezels using biomass-based PETG — reportedly the first application in the world. The optimized PETG/ABS composition was used to replace a PC/ABS blend. Benefits include a 57% reduction in carbon emissions (145 tons/year), an 88% reduction in VOCs, and a significant increase in molded part chemical resistance. By weight, the biomass content is 25% and by C14, the biomass content is 14%.

 

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 .

# # # # #

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




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