| Description |
|
Y-Seal Flip Window |
| OEM, Model, Model Year |
|
Ford, F250/350 , 2000 |
| System Supplier, Contact, Phone |
|
Donnelly Corporation, Simon Abbott, (616)786-7531 |
| Molder/Processor |
|
IPL |
| Material Supplier, Contact and Phone |
|
Advanced Elastomer Systems, L.P., Bonnie Bennyhoff, (248)377-6204 |
| Generic resin type |
|
TPV |
| Resin Trade Name |
|
Santoprene |
| Grade |
|
121-50M100 |
| OEM Engineer and Phone |
|
Doug Martinelli, (313)337-3766 |
| Nominated by, Company |
|
Peter Spencley, Donnelly Corporation |
| Address |
|
49 W. Third Street, Holland, MI 49423-2813 |
| Phone |
|
(616)786-7058 |
| Fax |
|
(616)786-7904 |
| Email |
|
simon.abbott@donnelly.com |
| Summary | | The first use of 2-shot injection molding to create a finished part having a redundant seal with a variable cross-section and with no limitation to corner radius design. By using the 2-shot molding process, the final system allowed stud placement to be optimized & a continuous seal vs the previous hand applied thermoset rubber "rope" design. Weight Savings: 25% Cost Savings: N/A Cost Avoidance: N/A |
| Most Innovative Feature | | The first use of 2-shot injection molding to create a finished part having a redundant seal with a variable cross-section and with no limitation to corner radius design. |
| Other Innovative Features | | By using the 2-shot molding process, the final system allowed stud placement to be optimized & a continuous seal vs the previous hand applied thermoset rubber "rope" design. |
| Forming Process | | 2-shot injection molding |
| First time process used? | | Yes |
| Previous Process Used | | TPEs have been used for this type of seal, but always hand-applied or insert-molded causing limitations on design/performance. This part previously used a hand-applied TSR seal. |
| Tooling Innovations | | Several modeling tools were used to optimize the seal: compressive load deflection curves were generated to design x-sectional areas for ideal sealing force over time. |
| New Material Developments | | The high-flow TPV used for this application did require a new material specification to be written at the OEM. |
| Weight Savings | | Versus the previous part, there was about a 25% weight savings. |
| Direct Cost Savings | | This will be submitted at a later time. |
| Indirect Cost Savings | | This will be submitted at a later time. |
| Direct Consumer Benefit | | ABSOLUTELY! reduced wind noise and water intrusion |
| Translates to other Vehicles? | | It's already being duplicated onto other platforms such as the U222/228. |
| Safety Benefits | | Driver visibility was enhanced because of the superior attachment system allowed as a result of using 2-shot molding. |
| Environmental Benefits | | The part is now completely recyclable versus the previous one. |