| Description |
|
Upper Bunk |
| OEM, Model, Model Year |
|
Freightliner , Century, 2001 |
| System Supplier, Contact, Phone |
|
Advance USA, Joel Santella, (248)546-0577 |
| Molder/Processor |
|
Advance USA |
| Toolmaker |
|
Midwest Patterns |
| Material Supplier |
|
GE Plastics/Dow Automotive |
| Generic resin type |
|
ABS / PU |
| Resin Trade Name |
|
Cycolac CGA / Polyurethane |
| OEM Engineer, Title and Phone |
|
Rocky Blakewood, Project Engineer, (503)745-6576 |
| Nominated by, Company |
|
Joel Santella, Advance USA |
| Address |
|
Rte 117 South , New Stanton, PA 15672 |
| Phone |
|
(248)546-0577 |
| Fax |
|
(248)546-2050 |
| Email |
|
jsantella@advanceusa.com |
| Summary | | Application combines the high strength & stiffness with impact resistance, aesthetics and weight reductions. Stiffness requirements include 6mm max deflection under 500 lb loading. Strength requirements 6,000 lbs impact simulation load. Design combined with the STRATA process allows for easy incorporation of additional. Weight Savings: 30 lbs Cost Savings: $28 to $175 Cost Avoidance: Reduced interior damage during bunk installation |
| Most Innovative Feature | | This application combines the high strength & stiffness typically found only in highly reinforced composites with impact resistance, aesthetics and weight reductions typically found with injection molded thermoplastics. Stiffness requirements for this application include 6mm max deflection under 500 lb loading. Strength requirements include 6,000 lbs impact simulation load. |
| Other Innovative Features | | This design combined with the STRATA process allows for easy incorporation of features such as a pin release mechanism and a cable trough with integrated cable retaining detents. |
| Forming Process | | The proprietary STRATA (tm) process is used to manufacture this application. Please see the attached process description. |
| First time process used? | | Yes |
| Previous Process Used | | This application replaces a welded aluminum tube frame with webbing for mattress support and a vinyl covering to provide the A surface trim. |
| Tooling Innovations | | N/A |
| New Material Developments | | A proprietary formulation of thermoset Polyurethane was developed for the reinforcements in this application. A mutilayer thermoplastic sheet structure combining cosmetic, chemical, and physical properties was developed for this application. |
| Weight Savings | | The strata bunk is 30 lbs lighter than the previous bunk frame. Once installed in the cab the bunk ass'y provides approx 10 lb weight reduction vs the previous technology. |
| Direct Cost Savings | | The STRATA bunk consolidated two similar but different bunk structures into one product. This provided a savings of $28 to $175 per bunk based upon the structure being replaced. |
| Indirect Cost Savings | | The sculpted corners of the bunk have reduced the rate of incidental interior damage caused during bunk installation |
| Direct Consumer Benefit | | Reduced opening/closing forces by 66% to a level comfortable for a 5th percentile woman. Improves interior styling by providing a styled appearance in an integrally molded low gloss, textured surface. Parts consolidation has significantly reduced SBR issues associated with the previous design. |
| Translates to other Vehicles? | | This application may be easily translated to other bunk applications as well as cabinets and other interior applications. The process may also be translated to applications such as Tonneau covers. |
| Environmental Benefits | | Product is produced with an environmentally friendly process that eliminates the emissions found in typical FRP or fabricated and painted structures. |
| Additional Info | | The STRATA composite allowed for the consolidation of numerous small parts into an integrated structure reducing the opportunity for quality or operational problems. |