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| Description: | Automated Wrap Floor Console | Model: | Cadillac STS |
| OEM: | General Motors | Model Year: | 2008 |
| System Supplier: | Dakota Systems | Generic Resin Type: | High Heat ABS |
| Molder/Processor: | Continental Plastics Co. | Resin Trade Name: | Magnum |
| Toolmaker: | ASI | Grade: | 975P |
| Material Supplier: | Dow Automotive | Other Innovative Features: | Unique bonding process involving heat and pressure used in conjunction with automated edge wrap tooling. |
| Most Innovative Feature: | Automated edge wrapping tooling for Interior trim applications. It is pneumatically driven. Continental Plastics' "Neu-wrap" technology. Also see bonding process below. | Forming Process: | Injection Molding |
| Weight Savings: | Weight savings is minor (5%). Thinner wall ABS and light weight adhesive provide small weight savings. | First Time Process Used? | Yes, it is the first time for this automated edge wrapping and bonding technology. The raw material configuration - ABS, Vinyl, and Special Adhesive is also a first. |
| Cost Savings: | Reduced labor (10 - 25% piece savings) | Previous Process: | Bladder wrapping with higher labor activity - more wrapping by hand. Leather and carpeting are the only known other materials that have been used to wrap a Floor Console. |
| Cost Avoidance: | Elimination of post trimming associated with vacuum wrapping technology. Tooling savings vs. vacuum wrapping. ($50,000 - $100,000 indirect tooling savings) | Transferable to Other Vehicles: | Yes, this application can be translated to other OEM's and other vehicle lines. It can also be used on other applications i.e. Door Panels, Garnish Trim and Instrument Panels. |
| Benefits to Consumer: | |||
| Soft Feel Interior parts are pleasing to the consumer. Also, some noise reduction results: both in BSR and NVH. Soft skin absorbs ambient sounds more and wrapped edges soften interfaces with other components. | |||
| Method Comments: | |||
| An unusual heat activated adhesive was developed for this application. High Heat ABS is used for the substrate to resist high process temperatures. | |||
| Innovations/Improvements: | |||
| Tooling innovations are in the automated edge wrapping fixtures. They are pneumatically driven and perform wet-out for bonding and consist of a patent, pending linkage system that automatically wraps the edges of the skin. | |||
| Safety Improvements: | |||
| N/A | |||
| Environmental Comments: | |||
| Reduced VOC's with waterbased adhesive is friendlier to the environment than a solvent based adhesive. Also, potential to develop trilaminate configueation of PP substrate, PP foam, and TPO shin allowing for easier non-stripping recycling. | |||
| Additional Comments: | |||
| Process allows for difficult shaped parts to be wrapped, Concave shapes and tight radie are possible. Other processes i.e. in-mold lamination have difficulty with tighter radii. | |||
| Summary: | |||
| This process is an automated edge-wrapping technology for interior trim applications. The unique bonding process involves heat and pressure used in conjunction with automated edge wrap tooling and yields improved fit and finish at reduced cost. | |||
