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automotive | SPE Awards


Above left: Moulded in Sabic’s Stamax LFT, the 2mm thick IP retainer for the current Jeep Cherokee won the Body Interior category


Above right: A two-step insert moulding process using PPA and PA was developed by ITW to produce this integrated coolant crossover for Ford’s V6 engines


of the mould space, using the empty centre section of the tool to mould the spoiler and rear window frame within the same cycle. The side window glazing used on the VW XL1 is the


fi rst commercial application of hard coated PC in a roll-down side glazing application. Developed by Sabic and Exatec (the material producer’s plasma hard coat technology subsidiary) in combination with specialist German mouldmaker SummererTechnologies, the two-component injection moulded parts deliver a system weight reduction of 33% over a 3.2mm glass alternative. Thermal insulation and misting resistance is also said to be improved (Injection World looked at this application in the March 2013 edition http://bit.ly/109i49h).


Interior innovations


First place in the Body Interior category went to the thin wall instrument panel (IP) retainer used on the 2014 Chrylser Jeep Cherokee SUV. Developed by Intertec Systems together with Sabic and Windsor Mold Group, the component is produced in Stamax 30K270 long fi bre reinforced PP and– at 2.0mm thick – is claimed to be the thinnest IP retainer on the North American market (alternatives are said to range from 2.5-4.0mm). The part meets all required stiffness, impact and safety standards but delivers a 30% cycle time saving and a 27% weight saving.


Right: One of the European


fi nalists in this year’s contest, Webasto’s


sunroof frame


for the Citroën DS3 Cabrio is moulded in


Xiran SMA/ABS blend from Polyscope


40


Runners up in the Body Interior category included IAC Group’s SmartFoil injection moulding technology, used on the 2014 Chevrolet Corvette Stingray and devel- oped together with material supplier Advanced Composites and toolmaker Hi-Tech Mold & Engineer- ing. The system uses back injection moulding onto a TPO foil to create an in-mould grained component that reduces weight by 5% and direct costs by 7%. It also offers improved scratch and mar resistance while the elimination of adhe- sives cuts VOC emissions.


IAC Group was also listed among the


fi nalists for a steering column cover it developed for the 2103 Ford Fusion with Advanced Composites


INJECTION WORLD | November/December 2013 www.injectionworld.com


and toolmaker Roush. Produced in a 20% talc-fi lled PP on two-cavity tooling, the component incorporates a living hinge which simplifi es installation of wiring on the assembly line. IAC claims a $1.10 saving on part cost and a $0.40 saving on cabling. In the Chassis/Hardware category, fi rst place went to the injection moulded bumper energy absorber developed by Magna Exteriors & Interiors for the 2013 Ford Fusion and Mondeo models. Injection moulded in Xenoy 1103 PC/PBT blend from Sabic, the component is claimed to be the fi rst to meet both the US Part 581 bumper damage and Pedestrian Protection GTR requirement for lower leg impact. The system can be tuned for different vehicle applications and offers a 40% weight and 10% cost reduction over steel. It is also said to be 20% lighter than alternative PP-based alternatives. Finalists in the category included the hidden handle


release mechanism developed by ITW for use on the 2013 Ford Ecosport SUV. Produced in Durethan BKV50 PA from Lanxess, the design integrates the handle mechanism into the tail lamp unit of the vehicle, creating an improved aesthetic but also considerably reducing component count and online assembly. The result is a good-looking part that cuts weight by 800g per vehicle and will deliver an annual direct cost saving of $1.2m and an indirect saving of $800,000.


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