The Society of Plastics Engineers (SPE) announced the winners and finalists for its 42nd Automotive Innovation Awards Competition on November 7, 2012 during a Gala at Burton Manor in the suburbs of Detroit, Michigan, USA. Winners and finalists of the category Body Interior were as follows. The category winner was also the winner of the SPE Grand Award. More details relating to other categories can be found in former and subsequent issues of Plastics.
Winner of the category Body Interior & Grand Award Winner
All-olefin, soft skin, stitched full IP system
The instrument panel with faux seam and contour stitching was the category winner as well as the Grand Award winner (photos: SPE)
OEM/vehicle: General Motors/2013 Buick Enclave, Chevrolet Traverse, GMC Acadia
System supplier: Inteva Products
Material processor: Inteva Products
Material suppliers: Adell Plastics, Stahl, Ticona Engineering Polymers
Resin: TPO-631 SSXT Soft TPO
Tooling/equipment supplier: KTX
These midsize crossover vehicles demonstrate the use of contour stitching on an all-olefin, multi-grained full instrument panel (IP) surface with complex geometry. Advanced robotic sewing technology provides an “uplevel” appearance while saving 15-25% costs vs. non-cut / sew applications and up to 50% vs. cut / sew leather plus 15% weight.
Finalist of the category Body Interior
Composite rear seat cushion frame
Rear seat cushion frame made of composite
OEM/vehicle: Hyundai Kia Automotive Group/2012 Kia K9
System supplier: Dymos
Material supplier: Honam Petrochemical
Resin: PP
Replacing a spot-welded steel structure with a one-shot, injection-moulded high-strength (long-glass/highcrystalline) PP composite allowed for development of a lightweight, low-cost rear seat cushion frame for a rearwheel-drive sedan. The application reduced weight 25% and costs 10% while improving the manufacturing process and has generated one Korean patent and two additional patents overseas.
Finalist of the category Body Interior
Dual purpose cargo management system lid
Cargo management system for a BEV
OEM/vehicle: Ford Motor/2012 Focus BEV
System supplier: The Woodbridge Group
Material processor: The Woodbridge Group
Material suppliers: JSP, BASF
Resins: EPP / PP
This patent-pending, dual-purpose, combination cargo management system / load floor for a BEV helps organise / store occupant goods while providing an adjustable load floor (with single-hand operation) and access to the battery charge door underneath without having to remove the unit from the vehicle.
Finalists of the category Body Interior
Inertial latch for console
Patented console-bin latching system
OEM/vehicle: Ford Motor/2013 Lincoln MKZ
System supplier: TRW Automotive
Material processor: TRW Automotive
Material suppliers: Ticona Engineering Polymers, DuPont Performance Polymers, Solvay Specialty Polymers
Resins: Celcon M90 POM, PA
Tooling/equipment supplier: TRW Automotive
A patented console-bin latching system that does not require a conventional paddle & hook feature was designed to offer better fit & finish, a flush appearance, and no ergonomic compromise, while still meeting FMVSS 201 requirements that the bin stay latched in a crash. This affords unique styling opportunities and the customer ability to simply lift open the console lid without the need to operate a latch. An inertial mechanism was combined with seatbelt retractor technology to lock the console when subjected to load. The latch is fully compliant with quality and safety requirements, yet there is no unsightly latch feature visible when the armrest is open. It is cost neutral and eliminates paint and chrome necessary for traditional latch decoration.
Finalist of the category Body Interior
Dolphin interior trim components
Instrument panel part
OEM/vehicle: Daimler/2011 Mercedez-Benz Actros
System supplier: Sole
Material processors: Trexel, Engel Austria
Material supplier: SO.F.TER
Resin: Pibiflex polyester based TPE
Tooling/equipment supplier: Georg Kaufmann
The new multi-phase Dolphin process allows a rigid substrate with integral foam core and MIC grained skin to be produced in one step on one machine. Equipped with an opposing, 2-barrel rotary platen with expansion / decompression option and utilizing the microcellular foam moulding process, the system moulds a rigid PC/ABS carrier, then forms a solid, MIC grained Class A outer skin (thickness adjustable by manipulating mould cooling time) as well as a low-density foam core layer (thickness / density are adjustable by altering the mould opening stops) from the same shot of TPE. The three layers maintain a strong bond without need for corona treatment. The parts reduced cost 25% vs. the previous PVC slush-moulded option, reduced process steps from eight to two, eliminated waste (since scrap from the all-thermoplastic system is fully recyclable and can be ground and reused).
