SPE Awards | automotive
The annual SPE Automotive Innovation Awards in the US highlight some of the world’s best examples of
plastics processing technology. Injection World takes a look at some of the best
injection moulding examples from the 2014 contest
Automotive awards put innovations in the spotlight
The sub-text for the SPE Automotive Division’s 43rd annual Innovation Awards – held in early November in Livonia, Michigan in the US – was ‘Plastics: kick the metal habit.’ And while many of the applications on the short list were great examples of plastics substituting metal, each also showed that plastics used intelligently are not simply a substitute but a far superior alternative to traditional materials. And that is down to the combination of the skill of part designers, the expertise of materials developers, and the process know-how of those that actually produce the components. This year’s overall Grand Award winner and winner of the Body Exterior category – the all-olefinic rear tailgate used on the 2014 Nissan Rogue crossover - is a great example. Developed by Hitachi Chemical and Magna Decostar together with materials suppliers LyondellBasell and US-based Advanced Composites and toolmaker Kyowa Industrial, the injection moulded tailgate offers a 30% weight saving over steel without compromising on quality or recyclability. In fact, the weight saving even makes it easier to use. The tailgate comprises two injection moulded panels
which are joined together using a structural adhesive. Hifax TYC1175P thermoplastic polyolefin (TPO) from LyondellBasell is used to produce the Class A outer panel, which is said to be a first for a North American vehicle. A self-coloured Mostran L5091-P long fibre reinforced
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polypropylene is used for the structural component, which also acts as the interior skin, producing a Class A interior finish without the need for painting. The Nissan tailgate beat off two other notable
applications in the Body Exterior category: the integrated semi-convertible sunroof frame used on the 2014 Citroën DS3 Cabrio and the polycarbonate side window glazing on VW’s super-fuel efficient XL-1 plug-in diesel hybrid car. The Citroën sunroof frame is a joint development
between Webasto and mouldmaker and moulder Shapers France and uses Xiran resin supplied by Polyscope. The part - which measures around 2,000mm by 1,000mm and is produced in Xiran SG230ED 15% glass reinforced styrene maleic anhydride/acryilonitrile butadiene styrene blend - runs the entire length of the roof and down to the shoulder-line of the car. Such a large
sunroof frame would normally be produced in an assembly of as many as seven aluminium extrusions or pressed steel parts; the Webasto solution replaces this with a single injection moulding that is 40% lighter. The Shapers’ engineers also made full use
November/December 2013 | INJECTION WORLD 39
Main image: Nissan’s
all-olefinic tailgate for the Rogue crossover
picked up the Grand Award
Below: The integrated handle and
light for Ford’s Ecosport SUV
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