|
WINNER |
|||
|
|
|||
|
(click on the picture to see a larger illustration - it opens in a new window, close that window to return here) |
|||
| Description: | Front End Carrier | Model: | Golf/Bora/Jetta |
| OEM: | Volkswagen | Model Year: | 2007 |
| System Supplier: | Aksys de Mexico | Generic Resin Type: | PP-LGF Inline Compound |
| Molder/Processor: | Aksys de Mexico | Resin Trade Name: | N/A |
| Toolmaker: | N/A | Grade: | N/A |
| Material Supplier: | Basell & Owens Corning | Other Innovative Features: | Replacing metal applications or GMT compression molded parts fo gain signigicant cost saving on material cost, no rework or secondary operation steps necessary |
| Most Innovative Feature: | Using Injection Molding Compounding process (Inline Injection Molding & Compounding) process for fully thermoplastic injection molded front-end molded carrier | Forming Process: | Injection Molding Compounding (Inline Injection Molding & Compounding) |
| Weight Savings: | Unknown - TBD | First Time Process Used? | YES in North America |
| Cost Savings: | Material cost saving up to 0.50 $/lbs | Previous Process: | Metal structure multiple parts - welding - assembly or GMT compression molding - punching - assembly |
| Cost Avoidance: | Rework, punching, assembly | Transferable to Other Vehicles: | Can be used for any PP-LGF application with throughput annual over 1 million lbs |
| Benefits to Consumer: | |||
| None | |||
| Method Comments: | |||
| None - Current PP grades (low to high meltflow) and standard glass fiber used | |||
| Innovations/Improvements: | |||
| None - all current technologies in tooling for processing LGF reinforced PP apply | |||
| Safety Improvements: | |||
| Passed all impact and vehicle crash tests | |||
| Environmental Comments: | |||
| None | |||
| Additional Comments: | |||
| Process becomes state-of-the art in Europe. Worldwide 40 systems running in production using this processing technology, approx. 10 for front-end module carrier applications | |||
| Summary: | |||
| This is the first direct-long fiber thermoplastic (D-LFT) composite front-end carrier compounded with a twin- instead of single-screw extruder during the inline compounding (ILC) portion of the process. ILC provides cost and weight savings vs. conventional injection and GMT composites, while also eliminating many secondary operations. | |||
