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FINALIST |
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(click on the picture to see a larger illustration - it opens in a new window, close that window to return here) |
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| Description: | Rear Seat Cushion Riser | Model: | X5 |
| OEM: | BMW | Model Year: | 2007 |
| System Supplier: | JSP International | Generic Resin Type: | Polypropylene |
| Molder/Processor: | JSP International | Resin Trade Name: | Arpro |
| Toolmaker: | JSP Mold | Grade: | N/A |
| Material Supplier: | JSP International | Other Innovative Features: | N/A |
| Most Innovative Feature: |
"This application combines two
different materials, steel stampings and expanded polypropylene bead
foam to provide a structural, lightweight replacement of
conventional steel stamped floor pans, while allowing common
architectures and assembly steps between 5 passenger and 7 passenger vehicles." |
Forming Process: | Insert Molded Steel in Expanded Polypropylene Steam Chest Molding |
| Weight Savings: | Estimated 3.9 kg savings over steel sub assembly | First Time Process Used? | No |
| Cost Savings: | Estimated $2.8 million savings in tooling investment | Previous Process: | Replaced need for secondary steel stamped floor pan assembly, allowing common floor pan assemblies to used for both 5 passenger and 7 passenger vehicles |
| Cost Avoidance: | Estimated $500k savings in equipment avoidance due to reduction in additional assembly steps | Transferable to Other Vehicles: | This application can be easily translated into other vehicles |
| Benefits to Consumer: | |||
| No | |||
| Method Comments: | |||
| None | |||
| Innovations/Improvements: | |||
| None | |||
| Safety Improvements: | |||
| No | |||
| Environmental Comments: | |||
| None | |||
| Additional Comments: | |||
| N/A | |||
| Summary: | |||
| This application
combines stamped steel and expanded PP bead foam to provide a
lightweight, structural replacement for conventional stamped steel
floor pans, while allowing common architectures and assembly steps
to be used between 5- and 7-passenger vehicles. Insert molding of
the steel / EPP foam component eliminated the need for secondary
assembly, and saved 3.9 kg of mass, $2.8-million USD in tooling
investment, and $500,000 USD in equipment avoidance vs. the previous
steel system. |
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