The 50th Annual Automotive Innovation Awards recognizes multiple “firsts” and new categories of innovative solutions for COVID-19 protection.#closeupontechnology
After having to skip a year due to the coronavirus pandemic, the 50th annual Society of Plastics Engineers Automotive Division’s Blue Ribbon Automotive Innovation Awards did not disappoint.There are several “firsts” in the seven main categories, with an additional category featuring innovative solutions to COVID-19.Since 1970, this oldest and largest competition of its kind highlights the positive changes that polymers are bringing to the automotive and ground transportation industries, such as reducing weight and cost, integrating parts, improving safety, and enhancing aesthetics and design freedom Spend.
Instead of selecting a single Hall of Fame (HOF) recipient for 2021, the HOF committee selected the top five leading innovations from the top 37 recipients from 1983 to 2019 in honor of the “50th Anniversary of Plastics Innovation.”HOF’s standard awards are nominated for at least 15 years of use and game-changing; very successful worldwide; innovation in materials, processes, and applications; and still in use.The top five for Hall of Fame awards are:
Meanwhile, the 2021 Vehicle Engineering Team Award (VETA) award went to Ford Motor Company and its suppliers for the team that developed the 2021 Ford F-150 pickup.The VETA Awards were created by SPE in 2004 to recognize the technical achievements of the entire team – automotive designers, engineers, tier integrators, material suppliers, tool makers and others – in research, design, engineering and/or Or manufacturing work has led to the integration of notable polymeric materials in well-known vehicles.Ford’s F-Series has been America’s best-selling pickup for 44 years, and the 2021 model features a raft of plastic and composite innovations, many of which were nominated in this year’s competition’s other categories, including exterior, interior, Chassis/Hardware and Materials
Additive manufacturing is used for an industry-first integrated tether system used throughout the Ford Maverick range.
Additive manufacturing is used to produce an industry-first integrated tether system where customers can select, download NFTL files and 3D print their own storage-friendly replaceable accessories (e.g. cup holders, trash cans, phone cord organizers, umbrella holders, etc.) Their vehicles have slots throughout the Ford Maverick range.More than 20 initial designs have been developed by Ford and its supply teams such as Tier 1 supplier IAC Group, but many future designs can be proposed by customers.Various printer types and suggested materials are available.This provides customers with flexible, customizable storage and usage capabilities, or the option to maximize cabin space while avoiding large tool investments.
This hard-coated and painted front PC grille with an illuminated logo provides a 3D futuristic effect in a single piece and is featured on the 2021 Ford Mustang Mach E GT.The Tier 1 supplier/processor is Magna Exterior and its LexaMar Div.Covestro is the material supplier, and the INEVIO Group is the tool manufacturer.Injection/compression molding creates large-format transparent PC grids with variable wall thickness (3 to 5 mm) in lower tonnage presses, helping to minimize or eliminate flow lines and stress marks.After molding, optical quality parts are impregnated with hardcoat silicone to provide weather and abrasion resistance; the pony logo is ground off; and primer and paint are selectively applied to the B side of the part – this is the The first use of hardcoat paint in automotive exterior applications.
This single-shot and shipping plastic component replaces the 16-piece steel component of the third-row seatback in the 2021 Toyota Sienna.
Another industry first is the replacement of 16-piece steel components on the 2021 Sienna Toyota’s third-row seat backs with single, shooting and shipping plastic parts.Tier 1 suppliers/processors are Toyota Boshoku Corp and Flex-N-Gate Corp.BASF is the material supplier and Concours Technologies is the tool manufacturer.Use BASF’s new Ultramid B3ZG7 CR, a 35% short-glass, impact-modified nylon 6 injection molding grade, to reduce weight by 30% and cost by 15%.In addition, this all-plastic free-standing seat back provides excellent energy absorption without the need for metal brackets and is said to triple crash performance, reducing the effort required by the occupant to raise the seat to an upright position by 63%, eliminating A seat motor is required.
The winner and grand prize winner in the Chassis/Hardware category is the thermoset multi-material rear leaf spring on the 2021 Ford F150.
This new hybrid rear leaf spring featured on the 2021 Ford F150 combines a high-strength steel main package with HP-RTM fiberglass-reinforced epoxy auxiliary to reduce mass by 30% while offering the same The same stiffness and durability as leaf springs.Tier 1 suppliers/processors are Rassini Suspensiones and SGL Carbon, and material suppliers are Hexion and SGL Carbon.Other benefits cited include increased payload capacity, reduced parts count, reduced intermediate friction, smoother engagement, lower noise and a lower carbon footprint.
These nylon 6 harness clips on the 2021 Ford Bronco Sport are injection molded from 100% PCR marine plastic.
These Injection Molded Recycled Nylon 6 Harness Clips on the 2021 Ford Bronco Sport are injection molded from 100% PCR marine plastic.Fishermen in the Indian Ocean and Arabian Sea collect “ghost gear” (abandoned fishing nets), providing jobs and healthier marine life.Tier 1 suppliers/processors are Lear and HellermannTyton North America.Material suppliers/tool manufacturers are DSM and HellermannTyton North America
DSM’s Akulon RePurposed Nylon 6 is melt compounded and is said to offer performance comparable to virgin premium resins while delivering 10% cost savings, lower energy usage, improved supply chain stability and LCA benefits.This drop-in replacement does not require any tool changes and minimal process changes.
The 2021 Stellantis Jeep Wrangler and Jeep Gladiator use 30 percent super-soft carbon fiber-reinforced PPA to replace investment-cast steel in six brackets for the removable hard-top and soft-top roofs.
The six brackets for removable hard and soft top roofs for the 2021 Stellantis Jeep Wrangler and Jeep Gladiator were converted from cast steel to 30 percent ultra-short carbon fiber (USCF) reinforced PPA.These injection-molded roof receivers provide comparable part strength while reducing cost by 38 percent and weight by 79 percent.
The Tier 1 supplier is Stellantis and the material suppliers/tool manufacturers are Mitsubishi Chemical Advanced Materials and Maple Mold Technology.Mitsubishi’s KyronMAX S-4340 PPA with 30% USCF allows for the elimination of powder coating, providing better scratch and mar resistance and weather resistance Class A finish, allowing for mid-term replacement and backward service compatibility.USCF composites are said to be moldable like pure polymers, yet perform better than long fiber (LFT) materials, are fully recyclable, and have a lower carbon footprint than metal/alloy parts.Drop valve gates and T-Nut fasteners are also key enablers.
2021 GM Cadillac Escalade (GM) Cadillac Escalade (GM) Cadillac Escalade (GM) Escalade (GM) This thick light bar for the Escalade (GM) developed through virtual prototyping, project time Shortened three months and avoided $250,000 in prototyping tooling costs.
This challenging 780mm long x 18mm thick, clear red light blade for rear taillights, featured on the 2021 GM Cadillac Escalade, has a unique look and uniform lighting appearance.
The Tier 1 Supplier/Processor is Valeo Lighting Systems and the Material Supplier/Tool Maker is Covestro and Windsor Mold Group.
Key to making the patent application work are advanced simulation tools for design and functional optimization and warpage control; complex runners, parting lines, shut-off valves, and multi-injection process control.Equally critical is Covestro’s Makrolon LED PC’s custom optical-grade optical-grade offering, which helps manage quality, cost, and moldability, and meets all legal taillight requirements.Despite technical challenges, project time was reduced by three months and $250,000 in prototyping tool costs were avoided through virtual prototyping.
Ford’s first all-plastic PARP converts metal parts to plastic to reduce mass and cost, and improve user comfort of this PPE used by medical staff treating COVID-19 patients.(All photos: SPE Automotive Division)
Ford’s 2020 NIOSH-certified limited-use APR (Powered Air Purifying Respirator) is the first all-plastic product of its kind, converting previously metal components to plastic to reduce weight and cost and improve user comfort.This personal protective equipment is used by medical staff caring for patients with COVID-19.
Tier and processor contributors are Ford and Denso.The material suppliers are Asahi Kasei America and Celanese, and the tool manufacturers are 3Dimensional Services and Protolabs.Asahi Kasei’s TD40 40% talc reinforced PP is used for injection molding snorkel adapters, filter caps, electronics caps and blower housings.The battery cover was transitioned from PP-TD40 to Celanese’s Hostaform/Celcon POM (polyacetal).
The lighter, more efficient design extends battery life, allowing workers to complete a 12-hour shift without needing to recharge the battery.Production increased from 650 pieces per week at the previous supplier to 8,500 pieces per week.All sales profits are donated to the COVID-19 Relief Fund.There are four patents pending for the device.
The big triennial plastics exhibition in Düsseldorf, Germany, next month challenges injection molding machine makers to demonstrate their technological leadership in meeting market demands.
A reversal of some of the factors driving prices could change course in the second or third quarter.
New York City Kuraray America introduces a new semi-aromatic high-temperature nylon to the U.S.
Post time: Jun-07-2022
