| Description |
|
Sequential Coinjected Bumper Fascia |
| OEM, Model, Model Year |
|
Ford, Explorer Sport Trac, 2001 |
| System Supplier, Contact, Phone |
|
Nascote Industries, Inc., Greg Niedzwiecki, (618)327-4381 |
| Molder/Processor, Contact and Phone |
|
Nascote Industries, Inc., Mike Smith, (618)327-4381 |
| Toolmaker, Contact and Phone |
|
Tycos Tool & Die / Synventive Molding Solutions, Tom Janicki, (248)729-4054 |
| Material Supplier, Contact and Phone |
|
Solvay Engineered Polymers, Tom Foley, (248)391-9519 |
| Generic resin type |
|
TPO |
| Resin Trade Name |
|
Sequel |
| Grade |
|
1440 |
| OEM Engineer, Title and Phone |
|
Shawn Morgans/Jim Niemiec, Ford Outfitters Body Exterior, (313)621-8455 |
| Nominated by, Company |
|
Greg Niedzwiecki, Nascote Industries, Inc. |
| Address |
|
18310 Enterprise Avenue, Nashville, IL 62263 |
| Phone |
|
(618)327-4381 |
| Fax |
|
(618)327-9817 |
| Email |
|
greg_niedzwiecki@nascote.com |
| Summary | | Bumper fascia is sequentially coinjected using painted TPO regrind and/or polypropylene in the core along with virgin TPO (with up to 20% unpainted regrind) outer skin. Fascia is partially painted, with a molded in color lower. Weight Savings: None. Cost Savings: TBD Cost Avoidance: Reduced waste removal cost. Avoid having to buy as much virgin TPO material. |
| Most Innovative Feature | | Bumper fascia is sequentially coinjected using painted TPO regrind and/or polypropylene in the core along with virgin TPO (with up to 20% unpainted regrind) outer skin. |
| Other Innovative Features | | Fascia is partially painted, with a molded in color lower. |
| Forming Process | | Co-injection molding utilizing sequential valve gating. |
| First time process used? | | Yes (Provisional patent waiting for approval). |
| Previous Process Used | | Single Injection Molding with straight virgin TPO (with up to 20% unpainted regrind). |
| Tooling Innovations | | Sequential valve gated hot runner manifold capable of co-injection. |
| New Material Developments | | Development and certification of core material - specification ASTM D4000 TEO 0120A45070GB093. Also required retesting the fascia to the paint performance specification along with retesting bumper impacts. |
| Weight Savings | | None. |
| Direct Cost Savings | | Currently evaluating the financial effects of grinding and reusing painted TPO regrind versus sending painted fascias to landfill. |
| Indirect Cost Savings | | Reduced waste removal cost. Avoid having to buy as much virgin TPO material. |
| Direct Consumer Benefit | | No. |
| Translates to other Vehicles? | | Yes. |
| Safety Benefits | | None. |
| Environmental Benefits | | Re-use painted TPO regrind versus sending to landfill. |
| Additional Info | | None. |