The Safety award winner was the side airbag cover on the 2013 Ford Fusion mid-size sedan. The part was manufactured from a TPO resin from Mitsubishi Chemical. The system supplier was Autoliv. The material processor is Atlantic Precision Products; the tooling and equipment supplier is Great Lakes Mold & Engineering.
Winner of the category Safety
Side airbag cover
OEM/vehicle: Ford Motor/2013 Ford Fusion mid-size sedan
System supplier: Autoliv
Material processor: Atlantic Precision Products
Material supplier: Mitsubishi
Resin: TT914 CNP TPO
Tooling/equipment supplier: Great Lakes Mold & Engineering
Replacing conventional metal cans and plastic covers, this is the first time an insert-moulded bracket/cover assembly has been designed to be both mounting surface for the seat side airbag (SAB) as well as integral to performance and cosmetic function of the cover. This unique design meets styling studio requests for a thin seat, but providing packaging space for increasingly large SABs, which now protect occupants from chest to pelvis. A cantilevered metal bracket allows for efficient assembly at the airbag supplier, reducing part counts and saving weight. Extensive filling and tooling development were used to ensure proper bracket encapsulation. Tough TPO resin maintains Class A appearance during normal use but delivers proper airbag deployment in a side-impact event.
Finalist of the category Safety
Collapsible armrest for side impact
OEM/vehicles: Ford Motor/2013 Ford Edge & Lincoln MKX CUVs
System supplier: Johnson Controls
Material processor: Johnson Controls
Material supplier: Styron
Resin: Magnum 3325MT ABS
Tooling/equipment supplier: Toolplas Systems
This injection-moulded armrest has been specially designed to maintain full integrity for NVH, comfort, aesthetics and durability during normal service life yet to detach and collapse during lateral loading from a side impact. Using PVC and ABS materials, the design features a single-piece insert and armrest with moulded-in slots that create a slip plane that is rigid enough for normal use but creates a failure path that provides for reduced occupant injury numbers. It also reduces material usage and costs 25% and a 15% reduction in assembly costs.