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SPE Awards | automotive


to the injection moulded cellulose fi bre composite console armrest


developed by Johnson


Controls in conjunction with Weyerhaeuser for the 2013 Ford Lincoln MKX. The part,


produced in Wekerhaeuser’s Thrive 20DX235PP grade with 20% cellulose fi bre content, costs the same as the glass


reinforced PP component it replaced but reduces CO2 emissions by 11% due to a combination of a 6% weight reduction and 10% process energy


reduction (the latter because the natural fi bre reinforced grade can be moulded at lower temperatures). Another Ford application was included in the


Environmental category fi nalists. The rear deck-lid applique and side door cladding on the 2015 Ford Mustang is produced in Amplas Compounding’s TAP01 TPO, which uses mineral fi bres and coconut powder in place of talc together with rubberised PP from recycled battery cases in place of virgin polymer. Tribar Manu- facturing produces the components, which provide a 15% material cost saving and 30% cycle time reduction due to the ability to reduce part wall thickness by 30%. Winning out in the Materials category was a


metallic-look panel injection moulded by Key Plastics Löhne for IAC for application in the 2015 Ford Mondeo. Produced in Luminous LX-1098 PC/ABS blend from Samsung Chemical, the complex geometry of the part includes a number of holes and an unforgiving smooth surface yet the fi nal result is a high gloss component with no sign of weldlines. Eliminating the need for painting is said to reduce direct costs by $13 a vehicle. The high quality fi nish is the result of the specially


developed resin, which incorporates an optimised metallic-fl ake size distribution, and special tooling developed by Michael Tool & Mould. This employs a combination of optimised hot runner and gate design, a special tool surface fi nish, continuous venting, and eMold temperature regulation system for running critical areas of the mould at raised temperature. Among the fi nalists in the Materials category was the Hushlloy HS210 ABS and ABS/PC resins developed by Techno Polymer America to reduce squeaking in automotive interior assemblies. The new materials use specially developed styrene copolymer in place of additives and other noise management measures to reduce stick/slip noise. Used on the 2104 Ford Taurus by Tier One supplier Summit Polymers, the resins are said to cut cost by $1 per car. The winning entry in the Body Interior category was a second row seat back produced in glass mat reinforced


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thermoplastic composite by Continental Structural Plastics for Ford’s 2015 Mustang. However, sensor maker TDK-EPC Corpora- tion made it to the fi nalist list with an all-plastic injection moulded temperature averaging


discharge sensor for the HVAC system in the 2014


Ford Fusion. The new design, produced in Bergamid PA6,6 and PA6 grades from PolyOne, eliminates the need


for a metal sensor plate and O-ring seal. The result is simplifi ed assembly and a 38% weight reduction. Details of all winners and fi nalists in the 2014 SPE


Automotive Innovation Awards can be found at the event website, where it is also possible to fi nd out about previous completion winners: http://speautomotive.com/awa


Click on the links for more information:  www.faurecia.comwww.advcmp.comwww.mcc-spd.comwww.shapecorp.comwww.lyondellbasell.comwww.dsmep.com  www.fl ex-n-gate.comwww.materialscience.bayer.comwww.groupe-plastivaloire.comwww.gscaltex.comwww.3dimensional.comwww.sabic.comwww.kwplastics.comwww.usfarathane.comwww.weyerhaeuser.comwww.amplascompounding.comwww.tribarmfg.comwww.keyplastics.comwww.samsungchemical.comwww.techpo.co.jpwww.summitpolymers.comwww.polyone.com


Left: TDK- EPC’s cabin air sensor, produced in PolyOne Bergamid PA, eliminates metal to provide a 38% weight saving


Left: This natural fi bre reinforced glove box cover used on the Ford Lincoln MKX cut weight by 6% and energy use by 11%


November/December 2014 | INJECTION WORLD 41


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