The first
high-volume pickup truck application to use an all-plastic system to fill,
store and deliver diesel exhaust fluid (DEF) was the 2010 Grand Award winner in
the SPE Automotive Innovation Awards competition.
Multiple
materials and molding processes are featured on this system, which is designed
to meet stringent diesel-emissions requirements.
The system
is used on the 2011 Ford Super Duty Pickup and was developed by Ford, Robert
Bosch and Kautex Textron GmbH and Co., along with several processors and
material suppliers.
Ninety
percent of the components in the assembly are polymeric, including the filler
pipe (which requires no clamps), plastic supply module with integrated pump,
reverting valve, pressure sensor, heater and filtration unit.
Additional
plastic components in the system include heated intake reservoir (with integral
heater), level sensor, filter and temperature sensor. The only other type of
material that could have withstood the DEF fluid would be stainless steel,
which would have been seven times heavier and cost 40 percent more.
The winners
of the 40th-annual SPE Automotive Innovation Awards competition, the oldest and
largest recognition event in the automotive industry, were announced on Nov. 9
by the Automotive Division of the Society of Plastics Engineers.
After a
pre-qualification round, surviving nomination teams presented their
applications before a panel of automotive and plastics industry experts during two
days of judging on Sept. 30 and Oct. 1. Finalists selected from each category
advanced to the Blue Ribbon Judging on Oct. 11 where category and Grand Award
winners were selected.
"We were
really pleased with the number of nominations we received this year, the
diversity of automakers represented, and the quality of innovation they
displayed," said Jeff Helms, 2010 Automotive Innovation Awards program chairman.
Finalists
and winners are:
CATEGORY: Body Exterior
Category winner: Dual Material
Sealing With PIT Technology
OEM and Model:
Ford 2011 model year Ford C-Max Compact Car
Tier
Supplier/Processor: Röchling Automotive Röchling Automotive Italia
Material:
Polypropylene (PP) and Ethylene Propylene Diene Monomer (EPDM)
Process: Projectile-injection technology (PIT).
Category Finalist: Nameplate Badge
OEM and Model:
Ford 2010 F150 Pickup
Tier
Supplier/Processor: Tribar Manufacturing
Materials Suppliers/Toolmaker:
SABIC Innovative Plastics and Ashland Distribution/Granby Tool Co.
Materials:
Acrylonitrile Styrene Acrylate (ASA)/Acrylonitrile Butadiene Styrene (ABS)
Process:
Injection Molding
Description:
This molded-in-color ASA and ABS design provides the appearance of a
paint-over-chrome badge without use of paint, leading to a significant cost
savings and quality improvement. Ford received a $1 million direct cost savings
on its F150 pickups and there were significant environmental benefits by
eliminating paint.
Category Finalist: Pillar Appliqué
OEM and Model:
Ford 2011 C-Max Compact Car
Tier
Supplier/Processor: Dura Automotive and Windsor Mold
Materials
Suppliers: EVONIK, BASF, and SABIC Innovative Plastics
Materials:
Acrylic and ABS
Process:
Injection Molding
Description:
This complex one-piece pillar appliqué uses vertical, two-shot rotational stack
molding to efficiently produce acrylic/ABS appliqués with integrated glass-run
channels and polyurethane (PUR) seals in a single part. The design eliminates
tape, and assures precise fit and minimal appliqué-to-glass offset for
world-class craftsmanship. Overmolding produces a significantly stronger part,
eliminating breakage and the need for impact
Category Finalist: Integrated Bumper
Energy Management Device
OEM and Model:
Ford 2011 model year Ford Edge Cross-Over Utility Vehicle
Tier
Supplier/Processor: Flex-N-Gate Corp.
Material
Supplier/Toolmaker: LyondellBasell/Concours Mold Inc.
Material:
Thermoplastic Polyolefin (TPO)
Process:
Injection Molding
Description:
This flexible TPO bumper fascia incorporates energy management into a one-piece
design, providing world-class appearance, structural integrity and impact
energy management, while reducing weight 50 percent, direct costs 20 percent
and indirect costs $1/vehicle.
Category Finalist: Bright Belt
Weather Strips With High Luster
OEM and Model:
Ford 2010 Fiesta Subcompact
Tier
Supplier/Processor: Cooper-Standard Automotive Inc.
Description:
Stainless steel was replaced by an injection-molded plated ABS cap that snaps into
place on the EPDM outer-belt weather-strip, providing a bright, body-in-white
finish, while still ensuring functionality. In addition, the change saved an estimated
$350,000 direct and $350,000 indirect cost annually, while reducing weight 428
grams per door.
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CATEGORY: Body InteriorCategory Winner: Self-Reinforced
Airbag Door SystemOEM and
Model: PSA Peugeot Citroën C5 Sedan
Tier
Supplier/Processor: Visteon Corp.
Material
Supplier: LyondellBasell and Propex Fabrics
Material:
Reinforced polypropylene (PP)
Process:
Injection Molding
Description:
This is the auto industry's first airbag door system that integrates an all-PP
construction (PP fiber-reinforced PP). As such, it is fully recyclable and does
not require typical post-mold scoring and weakening of the door flap. The
injection-molded door system is the lightest, least-expensive system solution,
since additional components and post-mold operations (to enable the door flap
to open) are eliminated. The resulting system reduced weight versus competitive
systems and saved approximately $5 per part versus welded systems.
Category Finalist: Heated
Steering-Wheel SystemOEM and
Model: Hyundai-Kia Motors Co. 2010 model year Kia Optima Sedan
Tier
Supplier/Processor: LG Hausys, Ltd.
Material: Polyurethane
Process:
Coating
Description:
This heated steering-wheel system uses reaction-injection molded polyurethane and
a unique sprayed-on, silver-impregnated coating-based heating element, which
was developed especially for this application. Heating is achieved by the
silver-based specialty coating rather than traditionally wrapped sewn-in
heating wire. Not only does the new system reduce weight by 50 percent (100 g)
and reduce tooling and assembly steps, but it also leads to a 5 percent direct
cost savings. In addition, it reduces risks of fire (since the unit operates
below 80C), produces more soothing, deep-penetrating far-infrared heat, and
also provides antibacterial properties.
Category Finalist: Interior Trim With
3-D Appearance OEM and
Model: Ford 2011 Explorer SUV
Tier
Supplier/Processor: Johnson Controls Inc.
Material
Supplier/Toolmaker: Dow Automotive/ ToolPlas Systems Inc.
Material:
ABS
Process:
Injection Molding
Description:
A new decorative option and an industry first allowed a technical pattern to be
injection molded into an interior trim component, preventing distortion in the
pattern in deep draw areas via graining of the substrate rather than
incorporating patterned paint film. This provides greater decorative
flexibility for the substrate to be molded-in-color, painted, or filmed-all
from the same tool. This led to a 10-20 percent variable cost savings due to
use of non-patterned films, and 100 percent avoidance of multiple substrate
tools for different decorative finishes, allowing easy and cost-effective model
differentiation.
CATEGORY: Chassis and HardwareCategory Winner: Integrated Carrier
Rail For Rear Plastic Door Module OEM and
Model: Hyundai Motors Co. 2010 Sonata Sedan
Tier
Supplier/Processor: PYEONG HWA Automotive and Arvin Meritor/Arkal Automotive
Material
Supplier/Toolmaker: SABIC Innovative Plastics/Aalbers Tool and Mold
Material:
Long-Fiber Thermoplastic (LFT)-PP
Process:
Injection Molding
Description:
Previous plastic door module designs had separate metal rails that are attached
to the module after molding. This innovative design has the window-regulator
guide rail molded as part of the plastic door module. Additionally, wire-harness
clips are normally a snap-in feature but in this design are integrated into the
module. And the drum housing, location pin, and door-handle bracket are also
integrated into the design.
Category Finalist: Structural
Composite Radiator SupportOEM and
Model: Ford 2010 model year Taurus Sedan
Tier
Supplier/Processor: Magna International Inc.
Material
Supplier/Toolmaker: Dow Automotive and Composites One/Century Tool and Gage
Material:
LFT-PP
Process:
Compression Molding
Description:
This structural composite radiator support is a single part capable of passing
a 5,340 N hood-latch pull test, while saving cost and weight. Compression
molded of direct-(inline-compounded) LFT-PP/glass and a glass-mat overlay (for
extra strength), the part reduced weight 33 percent, direct costs 20 percent
and also lowered part count, materials handling, and assembly time and replaced
coated steel and cast magnesium parts.
Category Finalist: Engine Cradle
Mount OEM and
Model: Ford 2011 model year Focus Sedan and C-Max Compact Car
Tier
Supplier/Processor: Hutchinson Paulstra/ThyssenKrupp Tallent Ltd.
Material Supplier/Toolmaker:
DuPont Automotive/SPLAST Sp
Material:
Thermoplastic Elastomer Ether Ester (TEEE)
Process:
Injection Molding
Description:
In this application, an injection-molded TEEE thermoplastic elastomer replaced thermoset
rubber thanks to the unique properties of the elastomer and a post-mold forming
step that used controlled insertion to achieve proper compression. This design
also takes advantage of the elastomer's ability to take a new material property
set in order to meet hysteresis requirements. Cost savings of 15 percent were
achieved, and cycle time was reduced 90 percent versus thermoset rubber.
Category Finalist: High-Duty
Lightweight Engine Mounts OEM and
Model: BMW AG 2009 model year BMW 550i and 750i Sedans
Tier
Supplier/Processor: ContiTech Vibration Control
Material
Supplier: BASF
Material: 50
percent-Glass-Reinforced (GR) Polyamide (PA, Nylon) 6/6
Process:
Injection Molding
Description:
For the first time, a highly loaded transmission cross-beam with integrated hydraulic
mounts was achieved in a lightweight plastic design thanks to use of
injection-molded, 50 percent-glass-reinforced PA 6/6. Replacing rubber/steel
and rubber/aluminum, the nylon assembly was designed to meet the rigorous
requirements of this application with regard to acoustics, crash, fatigue, and
high-temperature stability. The result was a 50 percent weight savings, as well
as in-house production integration at the systems supplier, leading to further
reductions in logistics and transportation costs.
Category: EnvironmentalCategory Winner: Recycled Polyol For
Seat Foam OEM and
Model: Chrysler Group LLC 2011 model year Chrysler Jeep Grand Cherokee SUV
Tier
Supplier/Processor: Magna Seating of America/MS Chemical Technologies (Magna)
Material
Supplier: InfiChem Polymers
Material:
Aromatic Polyether Polyols (Repolymerized Polyurethane (PUR)
Process:
Foamed Urethane
Description:
This is the first industrial production application of flexible urethane seat foams
produced with polyols manufactured from post-industrial scrap foam. A two-stage,
closed-loop recycling process converts the scrap foam back into a polyol
product, resulting in zero waste going to the landfill and allowing up to 10
percent recycled content in new parts. A unique process to reformulate the
reclaimed polyol to meet OEM specs was also developed for this application.
Neither weight nor direct cost were negatively impacted and an estimated $348,000 indirect cost savings was achieved.
Category Finalist: Bio-Based TPU Over
Recycled ABS Tambour Door OEM and
Model: Ford 2011 Lincoln MKZ Luxury Sedan
Tier
Supplier/Processor: International Automotive Components/Leon Plastics Inc.
Material
Supplier: Merquinsa and ACI Auto Group
Material:
Thermoplastic Polyurethane (TPU), Polycarbonate (PC), and ABS
Process:
Injection Molding
Description:
This is the auto industry's first use of a bio-based TPU, which was injection overmolded
on top of a PC-ABS derived from 100 percent post-industrial scrap. Both materials
were a drop-in replacement on the tambour door. While weight was the same, a
direct cost savings of $0.41/part was achieved while making the application
both more environmentally friendly and ensuring 100 percent recyclability at
end of part life.
Category: MaterialsCategory Winner:Turbocharged Engine
Cover OEM and
Model: General Motors 2010 model year GM Ecotec 2L Turbo Engine for
Cadillac CTS
Luxury Sports Sedan
Tier
Supplier/Processor: Camoplast Inc.
Material
Supplier/Toolmaker: DuPont Automotive/Camoplast
Material:
Polyamide Copolymer
Process:
Injection Molding
Description:
This injection-molded turbocharged engine cover features a PA copolymer with
new "Shield" technology for high-heat stability while doubling the heat-aging
property retention versus conventional nylons and some higher cost specialty
resins. The material handles the application's routine 180C service temperature
and periodic 200C temperature excursions while offering easy processing, good
surface finish, faster cycle times, and extended performance at up to 30
percent lower cost than specialty resins in this demanding under hood
application.
Category Finalist: On-Engine Oil
Filter Module OEM and
Model: Chrysler Group LLC Multiple/ 2010 model year Chrysler Pentastar Engines
Tier
Supplier/Processor: Hengst of North America, Inc.
Material
Supplier/Toolmaker: BASF Corp./VHM
Material:
Hydrolysis-resistant, 35 percent GR-PA 6/6
Process:
Injection Molding
Description:
This material is a hydrolysis-resistant PA 6/6 modified during polymerization
to increase hot glycol resistance at temperatures from 120-130C and to extend
hot-air heat-aging performance. It also offers reduced swelling and improved weld
strength in this application that is subject to oil and coolant contact.
Because of the material's higher heat and chemical resistance, it allowed this
large, spin-on oil-filter module to be mounted directly in the engine valley,
eliminating 148 parts, reducing weight 43 percent, and saving over 60 percent
direct costs, plus indirect costs owing to greater reliability.
Category Finalist: Seamless
Passenger-Airbag Instrument Panel TopperOEM and
Model: 2011 Ford Lincoln MKX CUV
Tier
Supplier/Processor: Automotive Components Holdings, LLC/ Leon Plastics Inc.
Material
Supplier/Toolmaker: Canadian General Tower Ltd./Leon Plastics Inc.
Material:
Polyvinyl Chloride (PVC)
Process:
Extrusion/Hand Wrapping
Description:
This seamless passenger-airbag IP topper molded from vinyl provides a
cost-effective alternative to more costly leather and synthetic-leather materials
made from urethane while providing upscale aesthetics. A special topcoat is
used to provide a low-squeak finish and to improve mar resistance. Like
previous materials, cut and sew stitching and hand wrapping via a bladder press
(for bonding) are used to join cover material to substrate.
Category Finalist: Reactor Grade
Talc-Filled Polypropylene OEM and
Model: 2011 model year Ford Explorer SUV
Tier
Supplier/Processor: NYX, Inc.
Material
Supplier/Toolmaker: Flint Hills Resources/Toolplas Systems Inc.
Material:
Reactor-Grade Talc-Filled PP
Process:
Injection Molding
Description:
In an industry first, reactor-grade, talc-filled PP was used to increase
stiffness in a quarter-trim panel while allowing a decrease in wallstock and
improvements in craftsmanship. By eliminating the burden of secondary compounding,
a lower carbon footprint was achieved and the supplier gained greater
lot-to-lot consistency, higher stiffness that allowed for thinner parts to be
molded (reducing mass 7 percent), and saving an estimated $500,000 annually
over precompounded PP grades.
Category Finalist: Low-Gloss,
Soft-Feel Resin OEM and
Model: Ford 2011 model year Ford Edge and Lincoln MKX CUVs
Tier
Supplier: Johnson Controls Inc.
Material Supplier/Toolmaker:
LyondellBasell/Toolplas Systems Inc.
Material:
Engineered Polyolefin
Description:
A new low-gloss, soft-touch TPO resin was developed, offering improved
aesthetics and greater durability. Previously, to achieve this combination of
properties, more costly wrapping or painting of the substrate was required. The
new applications, the first in North America, led to cost reductions of $4/part
versus painted and $5/part versus wrapped substrates.
Category Finalist: Nickel-Metal
Hydride (Ni-Mh) Battery Cell EnclosureOEM and
Model: BMW 2010 X6 Active Hybrid
Tier
Supplier/Processor: Cobasys LLC/PM Plastics Co.
Material
Supplier/Toolmaker: AsahiKasei Plastics/Arlen Tool Co. Ltd
Material:
Polyphenylene Ether (PPE)/PP Copolymer
Description:
This is the first use of engine coolant as a cell-cooling medium for Ni-MH battery
cells for a hybrid cross-over utility vehicle. A special PPE/PP copolymer
provides lightweight stiffness and creep resistance, plus seals out moisture for
this battery-cell enclosure while providing resistance to alkali battery and
coolant chemicals. The high-productivity resin provided excellent molding
productivity in thin walls. A special film-insert molding process and secondary
welding technology also were developed for this application. The unit saves an estimated
2.3 kg of weight versus alternative resins considered for the application.
CATEGORY: Performance And CustomizationCategory Winner: Chrome Film
Thermoformed Bumpers OEM and
Model: Ford/Retro USA 2009 model year Retro USA Limited-Edition "Bullit"
Mustang Sports Car
Tier
Supplier/Processor: Retro USA/Orion Plastics Inc. and Brentwood Industries,
Inc.
Material
Supplier/Toolmaker: Soliant LLC/Castek
Material:
Chrome Paint Film Over TPO
Process:
Thermoforming
Description:
This is the largest and thinnest chrome-film thermoformed TPO fascia to date.
The result is a lighter, less costly bumper cover that is more environmentally
benign. Low tooling costs make this technology very attractive for quick-change
transition parts at any production volume.
Category Finalist: Modular Sunvisor
Storage System OEM and
Model: Ford 2012 model year Mustang Sports Car
Tier
Supplier/Processor: Irvin Automotive Products, Inc./Fortis Plastics LLC
Material
Supplier/Toolmaker: Ticona Engineering Polymers/Yusei Holdings
Material:
Polyoxymethylene (POM, Acetal)
Process:
Injection Molding
Description:
This modular sun visor-based storage system functions as a low-cost alternative
to an overhead console to allow customer to customize storage for sunglasses,
garage-door openers, coin or CD holders, organizers for pen and notepad, as
well as cell phones. Interchangeable components injection molded from POM snap
in and lock onto the base on the sun visor, making changeover quick and easy.
Category Finalist: Dual-Lens
Cup-Holder Light OEM and
Model: Ford 2011 model year Explorer SUV
Tier
Supplier/Processor: Chicago Miniature Lighting
Process:
Injection Molding
Description:
In this next-generation interior-lighting application, a one-piece design
integrates primary illumination surface and show-surface lenses for improved
craftsmanship, 10 percent weight savings and $0.35 cost savings versus previous
2-piece lens designs. The design also reduced assembly costs and lowered
warranty issues.
CATEGORY: PowertrainCategory And Grand Award Winner:
Diesel Exhaust Fluid System - Category
And Grand Award Winner
(See
beginning of story for details)
Category Finalist: Thermoplastic Oil
Pan Module OEM and
Model: Chrysler Group LLC 2010 model year 5.7L V8 Hemi Engine
Tier
Supplier/Processor: MAHLE North America
Material
Supplier/Toolmaker: BASF Corp./Integrity Tool and Mold Inc.
Material:
Impact-Modified, 35 percent GR-PA 6
Process:
Injection Molding
Description:
A next-generation, all-plastic oil-pan module is specifically designed for this
trail-rated vehicle to be able to channel oil up hill on a 60 percent grade.
New levels of parts integration have incorporated the pan's windage tray with cam
scraper function, oil pickup tube, seal, fasteners and oil plug in an
injection-molded assembly that is joined via vibration and infra-stake welding.
The 35 percent glass-reinforced PA 6 base material was optimized for stone impact
and retention of mechanicals when exposed to hot oil, cold temperatures, and
road salts. Replacing stamped steel, quiet steel, and cast aluminum, the
all-plastic oil pan reduces weight 41 percent, saves 50 percent on tooling
costs, and eliminates 4 assembly operations.
Category Finalist: Electronic Throttle-Control
Actuator OEM and
Model General Motors Co. All (Global)
Tier
Supplier/Processor: Continental Automotive/Multiple
Material
Supplier: DSM Engineering Plastics
Material: PA
4/6 and Polybutylene Terephthalate (PBT)
Process:
Injection Molding
Description:
This electronic throttle-control actuator meets or exceeds all USCAR global standards
and focuses on mass reduction. The unit makes use of injection molded PA 4/6
and PBT resins to produce 7 innovative plastic components: an ultra-thin-wall
carbon fiber-reinforced PA 4/6 bushing, ultra-high-strength gears with
outstanding dimensional stability, high-temperature electric motor brush card,
and a uniquely designed cover/cap combination. In total, 43 g of weight were
saved on this program versus previous designs.
CATEGORY: Process, Assembly, And Enabling
TechnologiesCategory Winner: High Gloss Finish Without Paint OEM and
Model: Ford 2011 model year Escape SUV
Tier
Supplier/Processor: Summit Polymers
Material
Supplier/Toolmaker: Samsung Cheil Industries, Inc./Namdo Tool Co.
Material: PC
and ABS
Process:
Injection Molding
Description:
These are the first molded-in-color, high-gloss, jet-black ABS instrument
panel, console and door-finish panel applications produced by a modified
injection process that eliminates paint while avoiding molding defects such as
flow marks and knit lines. By increasing the cavity-side tool temperature to
between 110 and 160C, before and during injection, then quickly cooled down
before the part is injected, a highly aesthetic surface is achieved. A new
grade of ABS resin was developed to deliver deep, jet-black color while also
meeting head impact criteria. The application increased aesthetics, eliminated
paint, improve environmental compatibility, and lowered direct costs by 20-65
percent.
Category Finalist: Multi-Functional
Exchange Blow Molding Air Duct OEM and
Model: Suburu 2010 model year Legacy
Sedan and Outback CUV
Tier
Supplier/Processor: Excell USA
Material
Supplier/Toolmaker: Channel Prime Alliance and ExxonMobil Chemical/Excell Corp.
Material: PP
and PP/Thermoplastic Vulcanizate (TPV)
Process:
Multi-Functional Exchange Blow Molding
Description:
This multi-functional-exchange blow-molded air duct integrates the resonator, brackets
and pipe in a single step using a combination of hard HDPE and soft TPV resins
via a new process. The part replaced a combination of rubber hose, metal and
resin ducts, the resonator, and clamps with a single part produced in a single
process step where material change, wall thicknesses and inner pressure are all
controlled very precisely. The application saved an estimated 30-40 percent in
weight and 25-35 percent in both direct and indirect costs.
Category Finalist: Cam Cover With
Integrated Variable-Valve Timing OEM and
Model: Chrysler Group LLC 2011 model year Jeep Cherokee SUV
Tier
Supplier/Processor: Bruss NA
Material
Supplier/Toolmaker: BASF Corp./Active Burgess
Material: 35
percent GR-PA 6/6
Process:
Injection Molding
Description:
This is the first time that a plastic surface has been used for a cam variable
valve timing cam cover. Holding a positional tolerance of 0.5 mm and required
to pass 100 percent inspection, the application required development of a
special workstation with laser and optical measurement tools to verify
dimensional compliance. High-flow, 35 percent-glass-reinforced PA 6/6 was
injection molded for this application and replaced machined die-cast aluminum
while saving 2,200 grams and 25 percent direct material costs.
Category: SafetyCategory Winner: Inflatable Seatbelts
OEM and
Model: Ford 2011 model year Explorer SUV
Tier
Supplier: Key Safety Systems
Description:
Special tubular webbing used in the shoulder portion of rear seatbelts hides an
inflatable airbag that is triggered when front driver and passenger airbags are
triggered, protecting second- and third-row occupants, and particularly upper-
and lower-percentage occupants. During inflation, the airbag breaks through the
tubular webbing, expanding across the chest area and a special coating helps
the airbag stay inflated for 6 sec to protect for multiple crash modes. A new
weaving technique was used to form the tubular webbing and a frangible edge
that allows the belt to split and the airbag to deploy.
Category Finalist: Film For
Vacuum-Folded Airbag Application OEM and
Model: Ferrari 2010 model year 458 Italia Supercar
Tier
Supplier/Processor: Takata Corp.
Material
Supplier/Toolmaker: Bemis Assoc. Inc. and Schreiner Group/Takata Corp.
Material:
Co-Extruded Laminated Film
Process:
Film Extrusion/Vacuum Sealing
Description:
To meet styling trends for smaller airbag cushion package space without loss of
functionality, a packaging process common in the food and pharmaceutical
industries-vacuum-sealed films-has been applied to automotive safety restraints
for the first time. New tool design and manufacturing equipment were required
to produce the co-extruded, laminated vacuum-sealed pouches in order to meet
airbag performance requirements and environmental durability for the life of
the vehicle. Additionally airbag module mass was reduced by 15-30 percent and
package size was greatly reduced.
Category Finalist: Advanced Passenger
Airbag Chute OEM and
Model: Ford 2011 model year Lincoln MKX CUV
Tier
Supplier/Processor: Automotive Components Holdings
Material
Supplier: Mitsubishi Chemical USA
Material:
TPO
Process:
Injection Molding
Description:
A unique cavity/core tool design at the hinges allowed a special "hook and window"
feature to be created on this advanced passenger-airbag chute that intersects
the chute's inner wall rather than the top flange. The result is reduced squeak
and rattle, vertical support, and better PAB-to-chute alignment, as well as a
savings of 612 g and $4.36 per vehicle.
(Editor's Note: Design News Contributing
Editor Doug Smock was a member of the Blue Ribbon Judging panel that chose this
year's winners.)
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