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FINALIST |
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| Description: | Brush Grille Guard | Model: | Suburban, Tahoe, Avalanche |
| OEM: | General Motors | Model Year: | 2207 |
| System Supplier: | Algonquin Automotive | Generic Resin Type: | PP |
| Molder/Processor: | Composite Products, Inc. | Resin Trade Name: | Ineos |
| Toolmaker: | Delta Mold, Inc. | Grade: | H38G-02 |
| Material Supplier: | Composite Products, Inc. | Other Innovative Features: | High level of UV resistance, design and material used to minimize vibration and maximize driver comfort, molding process allows for reduction of assembly versus traditional manufacturing methods. |
| Most Innovative Feature: | A complete one-piece chrome tube that is the width of the vehicle is molded directly into the composite substrate in a one-step, in-mold operation. No secondary tube finishing operations are needed with this one-step molding process. | Forming Process: | Direct In-Line Compounding and Transfer Compression Molding |
| Weight Savings: | Weight savings of 50%. | First Time Process Used? | Yes |
| Cost Savings: | Cost savings of 50%. | Previous Process: | Metal weldments or assemblies, either with chrome tubes/bars, or painted/powder coated tubes/bars, some with a separate plastic or rubber beauty cover/protection over main steel structure. |
| Cost Avoidance: | Potential reduction of front-end damage in impact situations, saving repair costs. Could be as much as 75% lower replacement cost versus replacement of entire front end. | Transferable to Other Vehicles: | Part is specific to GM vehicles, but technology could be translated to other OEM's. |
| Benefits to Consumer: | |||
| Part was designed to eliminate vibration of component, material allowed for design to accomplish this without any secondary parts or steps. | |||
| Method Comments: | |||
| Custom formulation to limit color change due to UV exposure, more stringent than previous applications for longer part life. | |||
| Innovations/Improvements: | |||
| Complete shut-off of composite substrate at chrome tube interfaces (6 places). | |||
| Safety Improvements: | |||
| Allowed for the continued use of standard air bag deployment sensor, adds level of protection for front end impacts. | |||
| Environmental Comments: | |||
| Part is recyclable. Less chrome/paint needed vs. other methods. | |||
| Additional Comments: | |||
| First composite brush grille guard to utilize fiberglass reinforced thermoplastic material with the chrome tube molded-in direct. First utilization of Direct In-Line Compounding and Molding for a brush grille guard application. | |||
| Summary: | |||
| This is the first composite brush grille guard with a chrome tube overmolded by glass-reinforced thermoplastic; it is also the first use of the direct-LFT/compression molding process to produce this type of part. A custom resin formulation limits color change due to UV exposure for longer part life, and part weight and cost savings of 50% were seen vs. previous methods and materials. The part was designed to minimize vibration for increased passenger comfort, and to allow continued use of the standard airbag sensor, while improving protection to the vehicle’s front end in the event of impact, thereby potentially reducing repair costs (for a damaged front end) by up to 75%. | |||
