| Description |
|
HTPC Bumper Beam |
| OEM, Model, Model Year |
|
General Motors, Montana, Silhouette, Venture, 2002 |
| System Supplier, Contact, Phone |
|
Plastic Omnium, Matt Orlando, (248)853-0088 |
| Molder/Processor, Contact and Phone |
|
Plastic Omnium, Matt Orlando, (248)853-0088 |
| Toolmaker, Contact |
|
Collumn S.A., Husky, N/A |
| Material Supplier, Contact |
|
Vetrotex/Asahi Thermofil, N/A |
| Generic resin type |
|
PP + GF |
| Resin Trade Name |
|
Twintex |
| Grade |
|
4/1 P6-30FG0708 |
| OEM Engineer, Title and Phone |
|
Mark Campbell, Designing Engineer, (905)644-2674 |
| Nominated by, Company |
|
Dennis Wingate, Plastic Omnium Auto Exteriors |
| Address |
|
2610 Bond Street, Rochester Hills, MI 48309 |
| Phone |
|
(248)853-0088 |
| Fax |
|
(248)853-6973 |
| Email |
|
dwingate@poiusa.com |
| Summary | | Process allows the combination of glass filled polypropylene and continuous long glass fiber weave to form a hybrid thermoplastic composite (HTPC). HTPC beam exhibits 39% less intrusion during 5 mph pole test, 35% less intrusion for 5mph barrier, and 76% increase in static load capacity. Also eliminates energy absorbing foam. Weight Savings: 42% lighter than a typical steel beam Cost Savings: 27% over the previous product. Cost Avoidance: N/A |
| Most Innovative Feature | | Process used to manufacture the beam allows the combination of glass filled polypropylene and continuous long glass fiber weave to form a hybrid thermoplastic composite (HTPC) material. |
| Other Innovative Features | | The HTPC beam bumper Impact performance, energy absorption and effiency, exceed all other plastic/composite beams in its class. It eliminates both the need of a metal beam and energy absorbing foam. |
| Forming Process | | Thermoforming of Twintex sheets (60% glass weave); Thermoplastic Injection Molding; Water jet cutting. |
| First time process used? | | Yes. Plastic Omnium has obtained four patents for this product, and has 3 more under review. |
| Previous Process Used | | This process is unique because injection molding or thermoforming alone could not yield such a product. |
| Tooling Innovations | | 6-Axis robots used to handle Twintex sheets, stack, preform and insert them into the mold prior to injection. Also, the beams are finished by additional 6-axis robots in a water jet cutting cell. |
| New Material Developments | | None. |
| Weight Savings | | Same as GMT bumper beam systems, 42% lighter than a typical steel beam bumper system. |
| Direct Cost Savings | | 27% cost savings over the previous product. |
| Direct Consumer Benefit | | Significant improvement of impact performance. The beam is able to withstand two consecutive 5mph flat barrier impacts without replacement. The HTPC beam exhibits 31% less intrusion during a 5mph pole test over the previous product. |
| Translates to other Vehicles? | | It can be utilized across all vehicle lines. |
| Safety Benefits | | Improved bumper performance that maintains structural integrity after an impact. |
| Environmental Benefits | | N/A |
| Additional Info | | This process can be applied to a wide range of structural parts offering cost effective, environmentally friendly, and mass efficient parts. |