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Controlled Energy Management Bumper Isolator |
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| Application Description: Low cost injection molded Ultra-Thin Walled HDPE bumper isolator Conical Bumper Isolator manufactured from high flexural modulus material. | Single Most Unique Feature: The unique design offers a highly tunable square wave crash pulse and allows the isolator to meet all crash requirements in less package space and lower cost than EPP foam. |
| Process Descriptions: Ultra-Thin wall (1mm) precision injection molding hot runner tooling technology. | First Usage of Process?: This is the first ultra-thin walled isolator manufactured from stiff , high flex modulus material (150 ksi) at 1 mm wall stock and unique patented geometric shape. |
| Formerly Used Process: Previous injection molded isolators manufactured from soft EVA had wall stocks from 3.0 mm to 5.0 mm. Other isolators are foam or mechanical. | Tooling Innovations: An Industry first Dynisco hot runner manifold with over 100 hot drops, precisely delivers material to each cone individually filling them at 1mm wall stock. |
| Material Innovations: The material was engineered for maximum stiffness while keeping high flow rate(17 in./in.) cold impact performance and high ductility (600 % elongation). | Mass Savings: When optimized for package the new bumper isolator will result in a 2-6 lb system savings vs. EPP , 4-10 lb. vs EVA and 16 lb. vs mechanical. The highly efficient package space may allow slight downgage of crash structure. |
| Cost Savings:Engineered HDPE material ($0.45 vs. 2.15/lb. EPP, and molding process save between $7 to $12 vs. foam, $35 vs. mechanical isolators saving $40M/year. | Cost Avoidance: The smaller isolator package can reduce front and rear end overhangs saving $2 per vehicle. |
| Direct Consumer Benefit: The isolator package is smaller than EPP isolators reducing overhangs for improved styling. The unique crash pulse is not strain rate sensitive. The isolator absorbs more energy between 5 and 10 mph for less damage, possibly lowering insurance cost. | Is Technology Transferable?: The Isolator can be used on all vehicles with soft fascia's and the need to meet North American and/or European crash and /or bumper impact standards. |
| Significant Safety Benefit: The reduced package space allows the OEM to extend the body structure forward without increasing vehicle length for improved crash. | Significant Environmental Benefit: The isolator has been tested and produced with up to 75% post industrial/post consumer regrind. LDM will utilize recyclate when certified stock's available. |
| Additional Information: A unique patent-pending snap-lock design will allow the isolator to be molded in two-pieces. This allows the part to be manufactured in 2 pieces at a time on an existing small platen 800 ton press reducing overhead substantially. | Additional Information: NA |
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