| Description |
|
Laminate Insert Molded Instrument Panel |
| OEM, Model, Model Year |
|
Mazda, Tribute, 2001 |
| System Supplier, Contact, Phone |
|
Visteon Corporation, Marsha Helton, (734)429-6311 |
| Molder/Processor, Contact and Phone |
|
Visteon Saline, Frank Jarvis, (734)944-9720 |
| Toolmaker, Contact and Phone |
|
B & B Tool & Mould, Anthony Pelle, (519)737-1522 |
| Material Supplier, Contact and Phone |
|
ATC Inc. , Rob Morgan, (513)561-0525 |
| Generic resin type |
|
TPO + TF |
| Grade |
|
ATX-832 |
| OEM Engineer, Title and Phone |
|
Mr. Hiroshi Inoue, Chief Engineer - Mazda, (313)845-8179 |
| Nominated by, Company |
|
Cheryl L. Moore, Visteon Corporation |
| Address |
|
5500 Auto Club Drive, Dearborn, MI 48126 |
| Phone |
|
(313)755-1036 |
| Fax |
|
(313)755-1375 |
| Email |
|
cmoore10@visteon.com |
| Summary | | Creation of a partial "soft'" instrumental panel through insert molding of foam backed TPO skin. Creates a soft instrument panel which is fully recyclable. Another innovative feature of this application is that 100% of the manufacturing scrap (skin/foam/resin) are used to manufacture the Focus glove box bin. Weight Savings: 10%. Cost Savings: N/A. Cost Avoidance: Recycling of scrap, approx 1/2 million lbs per year. |
| Most Innovative Feature | | Creation of a partial "soft'" instrumental panel through insert molding of foam backed TPO skin. |
| Other Innovative Features | | The single most unique feature of this application is that it is a soft instrument panel which is fully recyclable. Another innovative feature of this application is that 100% of the manufacturing scrap (skin/foam/resin) are used to manufacture the Focus glove box bin. |
| Forming Process | | The processes used to produce this part are male vacuum forming and insert injection molding. |
| First time process used? | | This is the first time, in North America, that this process was used to produce this type of component. |
| Previous Process Used | | Two methods that were previously used for this application were RIM (Reaction Injection Molding) and FIP (Foam In Place). |
| Tooling Innovations | | n/a |
| New Material Developments | | TPO trilaminate skin material developed to meet instrument panel performance specifications |
| Weight Savings | | The estimated weight savings achieved versus alternative manufacturing methods is 10%. |
| Direct Cost Savings | | The direct cost savings is variable depending on the percentage of coverage. |
| Indirect Cost Savings | | Recycling is an indirect cost savings, which has been seen at approximately 1/2 million per year. |
| Direct Consumer Benefit | | Some direct consumer benefits include cost reduction over traditional panels, superior heat aging characteristics, weight reduction, and improved fit/finish and squeak/rattle results. |
| Translates to other Vehicles? | | Yes, this application can be translated to other vehicle lines. |
| Safety Benefits | | n/a |
| Environmental Benefits | | A significant environmental benefit is that the instrument panel is 100% recyclable. All scrap and offal from the instrument panel manufacturing process are being used for other products. |