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| WINNER |
Safety - Entry 19 |
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Pedestrian Protection Energy Absorber |
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| OEM: | Suzuki | |
| Model: | Swift | |
| Model Year: | 2005 | |
| System Supplier: | Takagi Seiko | |
| Molder / Processor: | Takagi Seiko | |
| Toolmaker: | Takagi Seiko | |
| Material Supplier: | GE Advanced Materials | |
| Generic Resin Type: | PC / PBT | |
| Resin Trade Name: | Xenoy | |
| Grade: | 1102 | |
| Summary: A polycarbonate (PC) / polybutylene terephthalate (PBT) front-end pedestrian-protection system weighing 1.5 lb less than a comparable steel design enables the Suzuki Swift to meet the European Union's Phase 1 lower-leg pedestrian-protection requirements within a 45-mm packaging space. | ||
| WINNER |
Safety - Entry 21 |
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Pedestrian Protection System |
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| OEM: | Volkswagen | |
| Model: | Golf | |
| Model Year: | 2004 | |
| System Supplier: | AKSYS GmbH | |
| Molder / Processor: | AKSYS GmbH | |
| Toolmaker: | Eppinger WF | |
| Material Supplier: | Quadrant AG | |
| Generic Resin Type: | Textile-Reinforced GMT | |
| Resin Trade Name: | GMTex | |
| Grade: | N/A | |
| Summary: A textile-reinforced glass-mat-thermoplastic (GMT) composite pedestrian-protection beam fulfills the European Unions' new pedestrian-protection safety standards on an existing vehicle design. Versus steel, the pedestrian-protection beam provides a 30% weight savings, 50% material cost savings, and 15% tooling cost savings, while also simplifying assembly and reducing recycling costs. | ||
| Finalist |
Safety - Entry 17 |
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Adaptive Front Lighting System |
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| OEM: | Mercedes-Benz | |
| Model: | E-Class | |
| Model Year: | 2003 | |
| System Supplier: | Hella KG Hueck & Co. | |
| Molder / Processor: | Ochsler AG, HUS GmbH | |
| Toolmaker: | Ochsler AG, HUS GmbH | |
| Material Supplier: | Ticona GmbH | |
| Generic Resin Type: | Liquid Crystal Polymer (LCP) | |
| Resin Trade Name: | Vectra | |
| Grade: | A625 | |
| Summary: Liquid crystal polymer (LCP) gearwheels and slide bearings help make possible the first-ever, active-cornering, Xenon headlamp system. Accommodating tight tolerances, high temperatures (180oC) and low gas release, the LCP gearwheels also satisfy mechanical requirements by enduring over 5-million swivel cycles without failure. Within milliseconds, the LCP slide bearings adjust shutter height, controlling light distribution, depending on beam mode, thereby increasing illumination by up to 50% and delivering a smooth, friction-free, reliable system. | ||
| Finalist |
Safety - Entry 18 |
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Active Energy Absorbing Steering Column |
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| OEM: | Ford | |
| Model: | Town Car / Grand Marque / Crown Victoria | |
| Model Year: | 2005 | |
| System Supplier: | Delphi Corporation | |
| Molder / Processor: | IER Industries / Plastic Solutions / Delphi Corporation | |
| Toolmaker: | N/A | |
| Material Supplier: | DuPont Automotive | |
| Generic Resin Type: | Acetal / PPA / Nylon | |
| Resin Trade Name: | N/A | |
| Grade: | N/A | |
| Summary: Numerous plastic components within this next-generation, adaptive energy-absorbing (EA) steering-column module enhance safety for a broader spectrum of drivers under a wider range of conditions. A nylon guide, a polyphthalamide (PPA) bushing, an acetal / magnesium break-away capsule, and a nylon / nitrile rubber / metal washer retaining ring are incorporated in the module. Depending on vehicle inputs, a pyrotechnic-activated device adjusts the load at which the steering column collapses at the instant of collision. In combination with a 2-stage airbag, these Ford vehicles achieved a 5-Star crash rating with minimal vehicle design changes. | ||
| Finalist |
Safety - Entry 67 |
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PU Foam for Side-Impact Performance Improvement |
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| OEM: | General Motors | |
| Model: | Cadillac DTS / Buick Lucerne | |
| Model Year: | 2006 | |
| System Supplier: | Dow Automotive | |
| Molder / Processor: | General Motors | |
| Toolmaker: | N/A | |
| Material Supplier: | Dow Automotive | |
| Generic Resin Type: | PU | |
| Resin Trade Name: | Betafoam | |
| Grade: | 89100/89124 | |
| Summary: Bulk, high-density, reaction-injection molded (RIM) polyurethane (PU) foam is injected into the cavity of the rocker panel in order to limit lateral structural deformation of the B-pillar in the case of a side impact. In addition to enhanced vehicle crash-safety performance, the RIM-containing BIW frame reduces costs vs. steel reinforcements by eliminating steel tools, paint-shop upgrades, as well as reduced assembly times per vehicle. | ||
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Safety - Entry 61 |
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Laser-Markable Tire-Pressure Monitor |
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| OEM: | Ford | |
| Model: | Multiple | |
| Model Year: | 2006 | |
| System Supplier: | Lear Corporation | |
| Molder / Processor: | Lear Corporation | |
| Toolmaker: | Great Lakes Mold | |
| Material Supplier: | GE Advanced Materials | |
| Generic Resin Type: | PBT | |
| Resin Trade Name: | Valox | |
| Grade: | N/A | |
| Summary: A laser-etchable polybutylene terephthalate (PBT) sensor monitors tire pressure and informs the driver. Each tire sensor is uniquely tagged by data that is etched into the sensor's body, thereby identifying sequenced manufacturing information. Vehicle safety performance is enhanced by minimizing the likelihood of operating the vehicle at improper tire pressures. | ||
