All-Plastic Exhaust System Tops SPE Auto Awards

The firsthigh-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 inthe SPE Automotive Innovation Awards competition.

Multiplematerials and molding processes are featured on this system, which is designedto meet stringent diesel-emissions requirements.

The systemis used on the 2011 Ford Super Duty Pickup and was developed by Ford, RobertBosch and Kautex Textron GmbH and Co., along with several processors andmaterial suppliers.

Ninetypercent of the components in the assembly are polymeric, including the fillerpipe (which requires no clamps), plastic supply module with integrated pump,reverting valve, pressure sensor, heater and filtration unit.

Additionalplastic components in the system include heated intake reservoir (with integralheater), level sensor, filter and temperature sensor. The only other type ofmaterial that could have withstood the DEF fluid would be stainless steel,which would have been seven times heavier and cost 40 percent more.

The winnersof the 40th-annual SPE Automotive Innovation Awards competition, the oldest andlargest recognition event in the automotive industry, were announced on Nov. 9by the Automotive Division of the Society of Plastics Engineers.

After apre-qualification round, surviving nomination teams presented theirapplications before a panel of automotive and plastics industry experts during twodays of judging on Sept. 30 and Oct. 1. Finalists selected from each categoryadvanced to the Blue Ribbon Judging on Oct. 11 where category and Grand Awardwinners were selected.

"We werereally pleased with the number of nominations we received this year, thediversity of automakers represented, and the quality of innovation theydisplayed," said Jeff Helms, 2010 Automotive Innovation Awards program chairman.

Finalistsand winners are:

CATEGORY: Body Exterior

Category winner: Dual MaterialSealing With PIT Technology
OEM and Model:Ford 2011 model year Ford C-Max Compact Car

TierSupplier/Processor: Rochling Automotive Rochling 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

TierSupplier/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 apaint-over-chrome badge without use of paint, leading to a significant costsavings and quality improvement. Ford received a $1 million direct cost savingson its F150 pickups and there were significant environmental benefits byeliminating paint.

Category Finalist: Pillar Applique
OEM and Model:Ford 2011 C-Max Compact Car

TierSupplier/Processor: Dura Automotive and Windsor Mold

MaterialsSuppliers: EVONIK, BASF, and SABIC Innovative Plastics

Materials:Acrylic and ABS

Process:Injection Molding

Description:This complex one-piece pillar applique uses vertical, two-shot rotational stackmolding to efficiently produce acrylic/ABS appliques with integrated glass-runchannels and polyurethane (PUR) seals in a single part. The design eliminatestape, and assures precise fit and minimal applique-to-glass offset forworld-class craftsmanship. Overmolding produces a significantly stronger part,eliminating breakage and the need for impact

Category Finalist: Integrated BumperEnergy Management Device
OEM and Model:Ford 2011 model year Ford Edge Cross-Over Utility Vehicle

TierSupplier/Processor: Flex-N-Gate Corp.

MaterialSupplier/Toolmaker: LyondellBasell/Concours Mold Inc.

Material:Thermoplastic Polyolefin (TPO)

Process:Injection Molding

Description:This flexible TPO bumper fascia incorporates energy management into a one-piecedesign, providing world-class appearance, structural integrity and impactenergy management, while reducing weight 50 percent, direct costs 20 percentand indirect costs $1/vehicle.

Category Finalist: Bright BeltWeather Strips With High Luster
OEM and Model:Ford 2010 Fiesta Subcompact

TierSupplier/Processor: Cooper-Standard Automotive Inc.

Description:Stainless steel was replaced by an injection-molded plated ABS cap that snaps intoplace on the EPDM outer-belt weather-strip, providing a bright, body-in-whitefinish, while still ensuring functionality. In addition, the change saved an estimated$350,000 direct and $350,000 indirect cost annually, while reducing weight 428grams per door.

CATEGORY: Body Interior

Category Winner: Self-ReinforcedAirbag Door System
OEM andModel: PSA Peugeot Citroen C5 Sedan

TierSupplier/Processor: Visteon Corp.

MaterialSupplier: 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-PPconstruction (PP fiber-reinforced PP). As such, it is fully recyclable and doesnot require typical post-mold scoring and weakening of the door flap. Theinjection-molded door system is the lightest, least-expensive system solution,since additional components and post-mold operations (to enable the door flapto open) are eliminated. The resulting system reduced weight versus competitivesystems and saved approximately $5 per part versus welded systems.

Category Finalist: HeatedSteering-Wheel System

OEM andModel: Hyundai-Kia Motors Co. 2010 model year Kia Optima Sedan

TierSupplier/Processor: LG Hausys, Ltd.

Material: Polyurethane

Process:Coating

Description:This heated steering-wheel system uses reaction-injection molded polyurethane anda unique sprayed-on, silver-impregnated coating-based heating element, whichwas developed especially for this application. Heating is achieved by thesilver-based specialty coating rather than traditionally wrapped sewn-inheating 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 directcost savings. In addition, it reduces risks of fire (since the unit operatesbelow 80C), produces more soothing, deep-penetrating far-infrared heat, andalso provides antibacterial properties.

Category Finalist: Interior Trim With3-D Appearance
OEM andModel: Ford 2011 Explorer SUV

TierSupplier/Processor: Johnson Controls Inc.

MaterialSupplier/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 beinjection molded into an interior trim component, preventing distortion in thepattern in deep draw areas via graining of the substrate rather thanincorporating patterned paint film. This provides greater decorativeflexibility for the substrate to be molded-in-color, painted, or filmed-allfrom the same tool. This led to a 10-20 percent variable cost savings due touse of non-patterned films, and 100 percent avoidance of multiple substratetools for different decorative finishes, allowing easy and cost-effective modeldifferentiation.

CATEGORY: Chassis and Hardware

Category Winner: Integrated CarrierRail For Rear Plastic Door Module
OEM andModel: Hyundai Motors Co. 2010 Sonata Sedan

TierSupplier/Processor: PYEONG HWA Automotive and Arvin Meritor/Arkal Automotive

MaterialSupplier/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 attachedto the module after molding. This innovative design has the window-regulatorguide rail molded as part of the plastic door module. Additionally, wire-harnessclips are normally a snap-in feature but in this design are integrated into themodule. And the drum housing, location pin, and door-handle bracket are alsointegrated into the design.

Category Finalist: StructuralComposite Radiator Support
OEM andModel: Ford 2010 model year Taurus Sedan

TierSupplier/Processor: Magna International Inc.

MaterialSupplier/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 passinga 5,340 N hood-latch pull test, while saving cost and weight. Compressionmolded of direct-(inline-compounded) LFT-PP/glass and a glass-mat overlay (forextra strength), the part reduced weight 33 percent, direct costs 20 percentand also lowered part count, materials handling, and assembly time and replacedcoated steel and cast magnesium parts.

Category Finalist: Engine CradleMount
OEM andModel: Ford 2011 model year Focus Sedan and C-Max Compact Car

TierSupplier/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 thermosetrubber thanks to the unique properties of the elastomer and a post-mold formingstep that used controlled insertion to achieve proper compression. This designalso takes advantage of the elastomer's ability to take a new material propertyset in order to meet hysteresis requirements. Cost savings of 15 percent wereachieved, and cycle time was reduced 90 percent versus thermoset rubber.

Category Finalist: High-DutyLightweight Engine Mounts
OEM andModel: BMW AG 2009 model year BMW 550i and 750i Sedans

TierSupplier/Processor: ContiTech Vibration Control

MaterialSupplier: BASF

Material: 50percent-Glass-Reinforced (GR) Polyamide (PA, Nylon) 6/6

Process:Injection Molding

Description:For the first time, a highly loaded transmission cross-beam with integrated hydraulicmounts was achieved in a lightweight plastic design thanks to use ofinjection-molded, 50 percent-glass-reinforced PA 6/6. Replacing rubber/steeland rubber/aluminum, the nylon assembly was designed to meet the rigorousrequirements of this application with regard to acoustics, crash, fatigue, andhigh-temperature stability. The result was a 50 percent weight savings, as wellas in-house production integration at the systems supplier, leading to furtherreductions in logistics and transportation costs.

Category: Environmental

Category Winner: Recycled Polyol ForSeat Foam
OEM andModel: Chrysler Group LLC 2011 model year Chrysler Jeep Grand Cherokee SUV

TierSupplier/Processor: Magna Seating of America/MS Chemical Technologies (Magna)

MaterialSupplier: InfiChem Polymers

Material:Aromatic Polyether Polyols (Repolymerized Polyurethane (PUR)

Process:Foamed Urethane

Description:This is the first industrial production application of flexible urethane seat foamsproduced with polyols manufactured from post-industrial scrap foam. A two-stage,closed-loop recycling process converts the scrap foam back into a polyolproduct, resulting in zero waste going to the landfill and allowing up to 10percent recycled content in new parts. A unique process to reformulate thereclaimed 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 OverRecycled ABS Tambour Door
OEM andModel: Ford 2011 Lincoln MKZ Luxury Sedan

TierSupplier/Processor: International Automotive Components/Leon Plastics Inc.

MaterialSupplier: 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 overmoldedon top of a PC-ABS derived from 100 percent post-industrial scrap. Both materialswere a drop-in replacement on the tambour door. While weight was the same, adirect cost savings of $0.41/part was achieved while making the applicationboth more environmentally friendly and ensuring 100 percent recyclability atend of part life.

Category: Materials

Category Winner:Turbocharged EngineCover
OEM andModel: General Motors 2010 model year GM Ecotec 2L Turbo Engine for

Cadillac CTSLuxury Sports Sedan

TierSupplier/Processor: Camoplast Inc.

MaterialSupplier/Toolmaker: DuPont Automotive/Camoplast

Material:Polyamide Copolymer

Process:Injection Molding

Description:This injection-molded turbocharged engine cover features a PA copolymer withnew "Shield" technology for high-heat stability while doubling the heat-agingproperty retention versus conventional nylons and some higher cost specialtyresins. The material handles the application's routine 180C service temperatureand periodic 200C temperature excursions while offering easy processing, goodsurface finish, faster cycle times, and extended performance at up to 30percent lower cost than specialty resins in this demanding under hoodapplication.

Category Finalist: On-Engine OilFilter Module
OEM andModel: Chrysler Group LLC Multiple/ 2010 model year Chrysler Pentastar Engines

TierSupplier/Processor: Hengst of North America, Inc.

MaterialSupplier/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 polymerizationto increase hot glycol resistance at temperatures from 120-130C and to extendhot-air heat-aging performance. It also offers reduced swelling and improved weldstrength in this application that is subject to oil and coolant contact.Because of the material's higher heat and chemical resistance, it allowed thislarge, spin-on oil-filter module to be mounted directly in the engine valley,eliminating 148 parts, reducing weight 43 percent, and saving over 60 percentdirect costs, plus indirect costs owing to greater reliability.

Category Finalist: SeamlessPassenger-Airbag Instrument Panel Topper
OEM andModel: 2011 Ford Lincoln MKX CUV

TierSupplier/Processor: Automotive Components Holdings, LLC/ Leon Plastics Inc.

MaterialSupplier/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 acost-effective alternative to more costly leather and synthetic-leather materialsmade from urethane while providing upscale aesthetics. A special topcoat isused to provide a low-squeak finish and to improve mar resistance. Likeprevious 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 GradeTalc-Filled Polypropylene
OEM andModel: 2011 model year Ford Explorer SUV

TierSupplier/Processor: NYX, Inc.

MaterialSupplier/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 increasestiffness in a quarter-trim panel while allowing a decrease in wallstock andimprovements in craftsmanship. By eliminating the burden of secondary compounding,a lower carbon footprint was achieved and the supplier gained greaterlot-to-lot consistency, higher stiffness that allowed for thinner parts to bemolded (reducing mass 7 percent), and saving an estimated $500,000 annuallyover precompounded PP grades.

Category Finalist: Low-Gloss,Soft-Feel Resin
OEM andModel: Ford 2011 model year Ford Edge and Lincoln MKX CUVs

TierSupplier: 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 improvedaesthetics and greater durability. Previously, to achieve this combination ofproperties, more costly wrapping or painting of the substrate was required. Thenew applications, the first in North America, led to cost reductions of $4/partversus painted and $5/part versus wrapped substrates.

Category Finalist: Nickel-MetalHydride (Ni-Mh) Battery Cell Enclosure
OEM andModel: BMW 2010 X6 Active Hybrid

TierSupplier/Processor: Cobasys LLC/PM Plastics Co.

MaterialSupplier/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 batterycells for a hybrid cross-over utility vehicle. A special PPE/PP copolymerprovides lightweight stiffness and creep resistance, plus seals out moisture forthis battery-cell enclosure while providing resistance to alkali battery andcoolant chemicals. The high-productivity resin provided excellent moldingproductivity in thin walls. A special film-insert molding process and secondarywelding technology also were developed for this application. The unit saves an estimated2.3 kg of weight versus alternative resins considered for the application.

CATEGORY: Performance And Customization

Category Winner: Chrome FilmThermoformed Bumpers
OEM andModel: Ford/Retro USA 2009 model year Retro USA Limited-Edition "Bullit"Mustang Sports Car

TierSupplier/Processor: Retro USA/Orion Plastics Inc. and Brentwood Industries,Inc.

MaterialSupplier/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 environmentallybenign. Low tooling costs make this technology very attractive for quick-changetransition parts at any production volume.

Category Finalist: Modular SunvisorStorage System
OEM andModel: Ford 2012 model year Mustang Sports Car

TierSupplier/Processor: Irvin Automotive Products, Inc./Fortis Plastics LLC

MaterialSupplier/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 alternativeto an overhead console to allow customer to customize storage for sunglasses,garage-door openers, coin or CD holders, organizers for pen and notepad, aswell as cell phones. Interchangeable components injection molded from POM snapin and lock onto the base on the sun visor, making changeover quick and easy.

Category Finalist: Dual-LensCup-Holder Light
OEM andModel: Ford 2011 model year Explorer SUV

TierSupplier/Processor: Chicago Miniature Lighting

Process:Injection Molding

Description:In this next-generation interior-lighting application, a one-piece designintegrates primary illumination surface and show-surface lenses for improvedcraftsmanship, 10 percent weight savings and $0.35 cost savings versus previous2-piece lens designs. The design also reduced assembly costs and loweredwarranty issues.

CATEGORY: Powertrain

Category And Grand Award Winner:Diesel Exhaust Fluid System - CategoryAnd Grand Award Winner

(Seebeginning of story for details)

Category Finalist: Thermoplastic OilPan Module
OEM andModel: Chrysler Group LLC 2010 model year 5.7L V8 Hemi Engine

TierSupplier/Processor: MAHLE North America

MaterialSupplier/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 thistrail-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 camscraper function, oil pickup tube, seal, fasteners and oil plug in aninjection-molded assembly that is joined via vibration and infra-stake welding.The 35 percent glass-reinforced PA 6 base material was optimized for stone impactand retention of mechanicals when exposed to hot oil, cold temperatures, androad salts. Replacing stamped steel, quiet steel, and cast aluminum, theall-plastic oil pan reduces weight 41 percent, saves 50 percent on toolingcosts, and eliminates 4 assembly operations.

Category Finalist: Electronic Throttle-ControlActuator
OEM andModel General Motors Co. All (Global)

TierSupplier/Processor: Continental Automotive/Multiple

MaterialSupplier: DSM Engineering Plastics

Material: PA4/6 and Polybutylene Terephthalate (PBT)

Process:Injection Molding

Description:This electronic throttle-control actuator meets or exceeds all USCAR global standardsand focuses on mass reduction. The unit makes use of injection molded PA 4/6and PBT resins to produce 7 innovative plastic components: an ultra-thin-wallcarbon fiber-reinforced PA 4/6 bushing, ultra-high-strength gears withoutstanding dimensional stability, high-temperature electric motor brush card,and a uniquely designed cover/cap combination. In total, 43 g of weight weresaved on this program versus previous designs.

CATEGORY: Process, Assembly, And EnablingTechnologies

Category Winner: High Gloss Finish Without Paint
OEM andModel: Ford 2011 model year Escape SUV

TierSupplier/Processor: Summit Polymers

MaterialSupplier/Toolmaker: Samsung Cheil Industries, Inc./Namdo Tool Co.

Material: PCand ABS

Process:Injection Molding

Description:These are the first molded-in-color, high-gloss, jet-black ABS instrumentpanel, console and door-finish panel applications produced by a modifiedinjection process that eliminates paint while avoiding molding defects such asflow marks and knit lines. By increasing the cavity-side tool temperature tobetween 110 and 160C, before and during injection, then quickly cooled downbefore the part is injected, a highly aesthetic surface is achieved. A newgrade of ABS resin was developed to deliver deep, jet-black color while alsomeeting head impact criteria. The application increased aesthetics, eliminatedpaint, improve environmental compatibility, and lowered direct costs by 20-65percent.

Category Finalist: Multi-FunctionalExchange Blow Molding Air Duct
OEM andModel: Suburu 2010 model year Legacy Sedan and Outback CUV

TierSupplier/Processor: Excell USA

MaterialSupplier/Toolmaker: Channel Prime Alliance and ExxonMobil Chemical/Excell Corp.

Material: PPand PP/Thermoplastic Vulcanizate (TPV)

Process:Multi-Functional Exchange Blow Molding

Description:This multi-functional-exchange blow-molded air duct integrates the resonator, bracketsand pipe in a single step using a combination of hard HDPE and soft TPV resinsvia a new process. The part replaced a combination of rubber hose, metal andresin ducts, the resonator, and clamps with a single part produced in a singleprocess step where material change, wall thicknesses and inner pressure are allcontrolled very precisely. The application saved an estimated 30-40 percent inweight and 25-35 percent in both direct and indirect costs.

Category Finalist: Cam Cover WithIntegrated Variable-Valve Timing
OEM andModel: Chrysler Group LLC 2011 model year Jeep Cherokee SUV

TierSupplier/Processor: Bruss NA

MaterialSupplier/Toolmaker: BASF Corp./Active Burgess

Material: 35percent GR-PA 6/6

Process:Injection Molding

Description:This is the first time that a plastic surface has been used for a cam variablevalve timing cam cover. Holding a positional tolerance of 0.5 mm and requiredto pass 100 percent inspection, the application required development of aspecial workstation with laser and optical measurement tools to verifydimensional compliance. High-flow, 35 percent-glass-reinforced PA 6/6 wasinjection molded for this application and replaced machined die-cast aluminumwhile saving 2,200 grams and 25 percent direct material costs.

Category: Safety
Category Winner: Inflatable Seatbelts

OEM andModel: Ford 2011 model year Explorer SUV

TierSupplier: Key Safety Systems

Description:Special tubular webbing used in the shoulder portion of rear seatbelts hides aninflatable airbag that is triggered when front driver and passenger airbags aretriggered, protecting second- and third-row occupants, and particularly upper-and lower-percentage occupants. During inflation, the airbag breaks through thetubular webbing, expanding across the chest area and a special coating helpsthe airbag stay inflated for 6 sec to protect for multiple crash modes. A newweaving technique was used to form the tubular webbing and a frangible edgethat allows the belt to split and the airbag to deploy.

Category Finalist: Film ForVacuum-Folded Airbag Application
OEM andModel: Ferrari 2010 model year 458 Italia Supercar

TierSupplier/Processor: Takata Corp.

MaterialSupplier/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 offunctionality, a packaging process common in the food and pharmaceuticalindustries-vacuum-sealed films-has been applied to automotive safety restraintsfor the first time. New tool design and manufacturing equipment were requiredto produce the co-extruded, laminated vacuum-sealed pouches in order to meetairbag performance requirements and environmental durability for the life ofthe vehicle. Additionally airbag module mass was reduced by 15-30 percent andpackage size was greatly reduced.

Category Finalist: Advanced PassengerAirbag Chute
OEM andModel: Ford 2011 model year Lincoln MKX CUV

TierSupplier/Processor: Automotive Components Holdings

MaterialSupplier: 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 intersectsthe chute's inner wall rather than the top flange. The result is reduced squeakand rattle, vertical support, and better PAB-to-chute alignment, as well as asavings of 612 g and $4.36 per vehicle.

(Editor's Note: Design News ContributingEditor Doug Smock was a member of the Blue Ribbon Judging panel that chose thisyear's winners.)