F the Society of Plastics Engineers

W e l c o m e to the 2010 Innovation Awards Gala

November 9, 2010

Welcome to the 40th-annual SPE Automotive Innovation Awards Gala, sponsored by the Automotive Division of the Society of Plastics Engineers. I am honored to chair this year’s program, the world’s oldest and largest recognition event in the automotive and plastics industries.

The automotive industry has begun a slow and steady recovery after the economic crisis of 2009. That recovery is evident in the number of nominations received for this year’s competition —up 20% from last year. What is very encouraging is that during the industry restructuring in 2008 and 2009, innovation had become even more important to the sustainability of the industry at large. The innovation we’ll be seeing in this year’s program ties in very well with this year’s event theme of Speed, Innovation and Value. Innovation in technology results in Speed to rapidly execute leading edge design and vehicle performance, and that, in turn, provides Value to consumers with quality products that meet or exceed their expectations at an affordable cost. The increase in nominations this year and the high amount of innovation they all represent is the result of investments made at a time when investment funds were very scarce. The creativity and determination of the men and women in this industry are a constant source of inspiration for us all.

Tonight’s program will recognize these accomplishments in specific vehicle categories and highlight those select individuals and teams with awards in the following: • Body Exterior • Performance & Customization • Body Interior • Safety • Chassis & Hardware • Hall of Fame • Lifetime Achievement Award • Past-Chair Award (SPE Automotive Division) • Materials • Process, Assembly & Enabling Technologies • Environmental • Powertrain, and • Vehicle Engineering Team Award • The Grand Award This year is also the 40th time our group has held this event. The Automotive Innovation Awards committee for SPE Automotive has searched our archives for special moments and reflections from the past 4 decades. Automotive and plastics engineers have demonstrated over the years that they are able to do what was once thought undoable. We will try to reflect on some of those advances during the program tonight and challenge ourselves to maintain the will to propel plastics even deeper into automotive design during the next 40 years of innovation.

Before we begin tonight’s program, I would like to thank the many volunteers, sponsors and judges who make this event possible. It is their dedication and commitment that enable the SPE Automotive Division to recognize the industry’s most significant advances in polymeric materials in automotive applications.

Welcome to the 40th-annual SPE Automotive Innovation Awards Gala. Thank you for joining us and we hope you enjoy the event. Jeff Helms Jeff Helms ’09 - ’10 SPE Automotive Innovation Awards Program Chair Chair, SPE Automotive Division Ticona Engineering Polymers

4 W e l c o m e Schedule of Events Blue Ribbon Judges 5:00-6:30 pm Reception / Mike Brady Preview of Nominated Parts & Vehicle Displays Reinforced Plastics magazine ______Pam Brady 6:30 pm Seating Begins Reinforced Plastics magazine ______Alexander Buechler Polymotive magzine 6:45-7:00 pm Welcome / Dinner Tony Deligio Jeff Helms, Ticona Engineering Polymers Injection Molding Magazine & and 2010 SPE Automotive Innovation Awards Program Chair Modern Plastics Worldwide Teri Chouinard, Intuit Group Subi Dinda Maria Ciliberti, Ticona Engineering Polymers Oakland University ______Ryan Gehm 7:00-9:00 pm Gala Program Automotive Engineering International Body Exterior James Kolb Tom Pickett, General Motors Co. American Chemistry Council-Plastics Division Body Interior Mike LeGault Yvonne Bankowski, Ford Motor Co. High-Performance Composites magazine Chassis & Hardware Josh Madden Bonnie Bennyhoff, ExxonMobil Chemical Mold Release Products Lifetime Achievement Award Peggy Malnati Fred Deans, Allied Composite Technologies LLC Composites Technology Magazine & Omnexus.com Materials Thomas Moore Norm Kakarala, Inteva Products Chrysler (retired) Environmental Allan Murray Monica Prokopyshen, SPE Automotive Division Allied Composite Technologies LLC, SPE Emeritus Vehicle Engineering Team Award Matthew Naitove Jeff Helms, Ticona Engineering Polymers Plastics Technology magazine Performance & Customization Irv Poston Kevin Pageau, Tegrant Corp. General Motors (retired) Safety Ron Price Bill Pippine, Takata Holdings LLC Global Polymer Solutions Hall of Fame Nippani Rao David Reed, David Reed Consulting LLC Rao Associates Past Chair Award Tom Russell Jeff Helms, Ticona Engineering Polymers Allied Composite Technologies LLC Process, Assembly & Enabling Technologies Mike Sammut Suresh Shah, Delphi Corp. MJS Consulting / Ford (retired) Powertrain Martina Schmieder Jane Aselage, Ford Motor Co. Polymotive magazine Grand Award Greg Schroeder Jeff Helms, Ticona Engineering Polymers CarGroup.com ______Roy Sjoberg Team R2S LLP 9:00-11:00 pm Afterglow Reception Doug Smock Everyone Invited to Attend Design News magazine Conrad Zumhagen The Zumhagen Company LLC

5 Gala & Afterglow Sponsor

Gold Sponsors

Silver Sponsors

Advertising Only Sponsor

6 Bronze Sponsors

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Media/Association Sponsors

2010 SPE Automotive Innovation Awards Competition & Gala Body Exterior

Charge-Port-Door Housing Assembly Fender with Pedestrian Head-Impact Absorber 2011 General Motors Co. Chevrolet Volt HEV 2011 Mitsubishi Motor Corp. Mitsubishi ASX CUV

System Supplier: ITW Deltar Fuel Systems System Supplier: Mitsubishi Motor Corp. Material Processor: ITW Deltar Fuel Systems Material Processor: Mitsubishi Motor Corp. Material Supplier: BASF, SABIC, DSM, RheTech Material Supplier: SABIC Innovative Plastics Resin: 8235G HS, GTX974, HIPP140, 5765B4, GC20P100-01 0 Resin: Noryl GTX GTX979 PPO/PA PA-GF50, PA66+PPE,ABS+PC, EPDM-TPE, PP-GF20 Tooling Supplier: Kyowa Industry Co. Ltd. Tooling Supplier: Flowline Tool & Mold Inc. & Industrial Tooling This front fender features special energy-absorbing structures that help To give the new Chevrolet Volt some extra sizzle, a plastics-intensive assembly protect pedestrian head-impact in the event of collision. Such a structure is was used to convert a conventional fuel-door housing to a charge-port-door usually made of steel and assembled separately between the side member system that protects the electric vehicle’s charge receptacle from dust and and the fender, but has been integrated in the fender design in this instance. water, while adding decorative chrome bezels, an actuated door with a Despite the injection-molded part’s thin part wall and deeply shaped design, damped system, and a double-lip-seal design. Multiple materials and injection it maintains precise gap and flush management. By eliminating steel, 3 kg of molding were selected for the complete assembly. weight was saved.

Bright Belt Weatherstrips with High Luster 2010 Ford Motor Co. Ford Fiesta Subcompact

System Supplier: Cooper-Standard Automotive Inc. Material Processor: Cooper-Standard Automotive Inc. Material Supplier: Not Available Resin: Not Available Tooling Supplier: Not Available Stainless steel was replaced by an injection-molded plated ABS cap that snaps into place on the EPDM outer-belt weatherstrip, providing a bright, body-in- white finish, while still ensuring functionality. In addition, the change saved an estimated $350,000 USD direct and $350,000 USD indirect cost annually, while reducing weight 428 g per door.

10 2010 SPE Automotive Innovation Awards Competition & Gala Body Exterior

Powder-Coated Plastic Roof-Rack Cover Integrated Bumper Energy Management Device 2009 Škoda Auto a.s. Škoda Yeti Mini-SUV 2011 Ford Motor Co. Ford Edge CUV

System Supplier: ACL System Supplier: Flex-N-Gate Corp. Material Processor: MSSL Material Processor: Flex-N-Gate Corp. Material Supplier: SABIC Innovative Plastics Material Supplier: LyondellBasell Resin: NORYL GTX 674PC PPO+PA Resin: Hifax Tyc773 Tooling Supplier: MSSL Tooling Supplier: Concours Mold Conductive, powder-coatable MPPE/PA resin was used for this plastic This injection-molded flexible TPO bumper fascia incorporates the roof-rack cover to ensure perfect color-match (metal-to-plastic) at lower cost energy-management device into a one-piece design, providing world-class vs. liquid paint. Not only were VOCs (from conventional paint) eliminated, but appearance, structural integrity, and impact energy management, while a 30% direct cost savings was also achieved. reducing weight 50%, direct costs 20%, and indirect costs $1/vehicle.

Nameplate Badge 2010 Ford Motor Co. Ford F150 Pickup

System Supplier: Tribar Manufacturing Material Processor: Tribar Manufacturing Material Supplier: SABIC Innovative Plastics / Ashland Distribution Resin: Cycolac MG37 ASA & Plating Grade ABS Tooling Supplier: Granby Tool This molded-in-color ASA and ABS design provides the appearance of a paint- over-chrome badge without use of paint, leading to a significant cost savings and quality improvement. The injection-molded part’s snap-together design reduces cost, has less scrap and rework, eliminates paint adhesion issues, and allows simple series-differentiation via material / finish changes on insertion. The OEM also saw a $1-million USD direct cost savings on its F150 pickups, and there were significant environmental benefits by eliminating paint.

1111 2010 SPE Automotive Innovation Awards Competition & Gala Body Exterior

Low-Gloss Coatings on TPO Hood Molding Dual Material Sealing with PIT Technology 2011 General Motors Co. Chevrolet Volt 2011 Ford Motor Co. Ford C-Max Compact Car

System Supplier: A.P. Plasman System Supplier: Röchling Automotive AG Material Processor: A.P. Plasman Material Processor: Röchling Automotive Italia srl Material Supplier: LyondellBasell Material Supplier: Softer SpA Resin: Sequel 1828 TPO Resin: PP+EPDM Tooling Supplier: Not Available Tooling Supplier: Röchling Automotive Italia srl This injection-molding application features a new type of hood molding – on Projectile-injection technology (PIT) allowed a hollow EPDM bulb seal to be the rear of the hood with a special low-gloss coating – to enable a particular co-molded with a PP cowl grille in a single process step, producing a single look desired by the styling studio. A TPO was selected as the base resin part. By fixing the precise position of the seal, quality improvements were because of its excellent dimensional stability to limit cross-car growth. Then gained during assembly, lower and more easily tunable compression force special low-gloss base-coat/clear-coat paint replaced a low-gloss mono-coat was achieved, and greater freedom in designing the seal’s path was accom- system to create an impactful styling feature. plished, saving 30% weight (vs. a separate, extruded seal) and 10% direct costs.

Pillar Appliqué Roof Ditch Molding 2011 Ford Motor Co. Ford C-Max Compact Car 2011 Ford Motor Co. Ford F150 Pickup

System Supplier: Dura Automotive & Windsor Mold System Supplier: SRG Global, Inc. Material Processor: Dura Automotive & Windsor Mold Material Processor: SRG Global, Inc. Material Supplier: Evonik / SABIC Innovative Plastics / BASF Corp. Material Supplier: Multibase, Inc. / A. Schulman, Inc. Resin: Acrylic / ABS & Urethane Resin: TPV / Long Glass PP Tooling Supplier: Not Available Tooling Supplier: Proper Mold & Engineering Inc. This complex one-piece pillar appliqué uses vertical, 2-shot rotational stack Two-shot rotational molding was used for the first time to produce this molding to efficiently produce acrylic / ABS appliqués with integrated roof-ditch molding, eliminating 100% of the assembly labor while providing glass-run channels and polyurethane (PUR) seals in a single part. The design significantly improved craftsmanship. Use of 40% LFT-PP in this applica- eliminates tape, and assures precise fit and minimal appliqué-to-glass offset tion yielded a stiffer part than the aluminum it replaced, leading to more for world-class craftsmanship. Overmolding produces a significantly stronger consistent fit with the exterior sheet metal. An overmolded TPV seal was part, eliminating breakage and the need for impact modifiers. Special scratch- customized to improve bonding to the PP substrate. Weight was reduced resistant additives improve long-term finish. Additional benefits include 15% and cost is 55% lower, saving the OEM $1.2 million USD annually. 15-25% lower weight and approximately $12 USD direct cost savings.

12 2010 SPE Automotive Innovation Awards Competition & Gala Body Interior

Heated Steering-Wheel System Inside Handle / Tweeter / Bezel Wrap Around 2010 Hyundai-Kia Motor Co. Kia Optima Sedan 2010 Ford Motor Co. Ford Explorer SUV

System Supplier: LG Hausys Material Processor: LG Hausys System Supplier: Johnson Controls Inc. Material Supplier: LG Hausys Material Processor: Johnson Controls Inc. Resin: PU RNF9008 Urethane Material Supplier: Not Available Tooling Supplier: LG Hausys Resin: Not Available Tooling Supplier: Not Available This heated steering-wheel system makes use of reaction-injection molded PUR and a unique sprayed-on, silver-impregnated coating-based heating This is industry’s first all-plastic, inside handle / tweeter speaker / bezel element, which was developed especially for this application. Heating release module. The injection-molded, plated system provides outstand- is achieved by the silver-based specialty coating rather than tradition- ing fit and finish as well as function. It simplifies the assembly sequence for ally wrapped / sewn-in heating wire. Not only does the new system reduce the tier 1, while saving an estimated 43% in weight and 30% in cost vs. the weight by 50% (100 g) and reduce tooling and assembly steps, but it also previous system. leads to a 5% direct cost savings. In addition, it reduces risks of fire (since the unit operates below 80C), produces more soothing, deep penetrating far-infrared heat, and also provides antibacterial properties.

Interior Trim with 3-D Appearance Mold-in Metallic Handle Cover 2011 Ford Motor Co. Ford Explorer SUV 2010 Ford Motor Co. Ford Fiesta Subcompact

System Supplier: Johnson Controls Inc. System Supplier: Faurecia Material Processor: Johnson Controls Inc. Material Processor: Faurecia Material Supplier: Dow Automotive Material Supplier: Ticona Engineering Polymers Resin: Magnum MT3325 ABS Resin: Celcon UV90Z Acetal Tooling Supplier: ToolPlas Systems Inc. Tooling Supplier: Omega Tool, Inc. A new decorative option and an industry first allowed a technical pattern to This molded-in-color application uses a metallic finish to replace paint on this be injection molded into an interior-trim component, preventing distortion handle cover, saving 49% direct costs. in the pattern in deep-draw areas via graining of the substrate rather than incorporating patterned paint film. This provides greater decorative flexibility for the substrate to be molded-in-color, painted, or filmed – all from the same tool. This led to a 10-20% variable cost savings due to use of non-patterned films, and 100% avoidance of multiple substrate tools for different decorative finishes, allowing easy and cost-effective model differentiation.

13 2010 SPE Automotive Innovation Awards Competition & Gala Body Interior

Self-Reinforced Airbag-Door System 2007 PSA Citroën Citroën C5 Sedan

System Supplier: Visteon Corp. Material Processor: Visteon Corp. Material Supplier: LyondellBasell & Propex Fabrics Resin: PP / PP Tooling Supplier: Not Available This is the auto industry’s first airbag-door system that integrates an all-PP construction (PP-fiber-reinforced PP). It is fully recyclable and does not require typical post-mold scoring / weakening of the door flap. The injection-molded door system is the lightest, least-expensive system solution, since additional components and post-mold operations (to enable the door flap to open / hinge) are eliminated. Multi-zone temperature control of the mold was required, as was use of a vacuum-holding system for the fabric insert. The program also required development of a specialized fiber-reinforced material to facilitate overmolding and subsequent adhesion. The resulting system reduced weight between 30% and 300% vs. competitive systems and saved approximately $5 USD/part vs. welded systems. Additional indirect savings of approximately 5% were also accrued, and production scrap is 100% recyclable.

14 2010 SPE Automotive Innovation Awards Competition & Gala Chassis/Hardware

Structural Composite Radiator Support 2010 Ford Motor Co. Ford Taurus Sedan

System Supplier: Magna International Inc. Material Processor: Magna International Inc. Material Supplier: Dow Automotive & Composite One Resin: PP Tooling Supplier: Century Tool & Gage This structural composite radiator support is a single part capable of passing a 5,340 N hood-latch pull test, while saving cost and weight. Compression molded of direct-(inline-compounded) LFT-PP / glass and a glass-mat overlay (for extra strength), the part reduced weight 33%, direct costs 20%, and also lowered part count, materials handling, and assembly time, while replacing coated-steel and cast-magnesium parts.

Power Window Motor Integrated Carrier Rail for Rear Plastic Door Module 2010 Ford Motor Co. Ford Focus Compact Car 2010 Hyundai Motor Co. Hyundai Sonata Sedan

System Supplier: Brose North America System Supplier: PYEONG HWA Automotive / Arvin Meritor Material Processor: Brose North America Material Processor: ARKAL Automotive Material Supplier: Not Available Material Supplier: SABIC Innovative Plastics Resin: Not Available Resin: Stamax 30YM240 PP+LGF Tooling Supplier: Not Available Tooling Supplier: Aalbers Tool & Mold Industry’s first injection-molded press-fit plastic-output pinion on this power- Previous plastic door module designs had separate metal rails that were window motor helps give the regulator plug & play capabilities into the attached to the module after molding. This innovative design has the power drum while reducing noise and weight vs. steel. No functionality has window-regulator guide rail molded as part of the plastic door module. been compromised: packaging of the involute on the spline gear to the Additionally, wire-harness clips are normally a snap-in feature but in this accompanying drum spline was a critical feature for the customer and it has design are integrated into the module. And the drum housing, location pin, been met successfully. Direct cost savings of $250,000 USD and indirect cost and door-handle bracket are also integrated into the design. savings of $150,000 USD were also achieved.

15 2010 SPE Automotive Innovation Awards Competition & Gala Chassis/Hardware

High-Duty Lightweight Engine Mounts Battery-Cover Assembly 2009 BMW AG BMW 550i & 750i Sedans 2011 General Motors Co. Chevrolet Volt HEV

System Supplier: ContiTech Vibration Control GmbH System Supplier: GM Brownstown Material Processor: ContiTech Vibration Control GmbH Material Processor: Continental Structural Plastics Material Supplier: BASF SE Material Supplier: Continental Structural Plastics Resin: Ultramid A3WG10CR PA 66 GF 50 Resin: Low / Med. Density Unsat. Polyester SMC Tooling Supplier: Not Available Tooling Supplier: Century Tool & Gage For the first time, a highly loaded transmission cross-beam with integrated This 1-piece, compression-molded battery-cover assembly in sheet-molding hydraulic mounts was achieved in a lightweight plastic design thanks to use compound (SMC) covers and seals the battery packs as received and is of injection-molded, 50%-glass-reinforced PA 6/6. Replacing rubber/steel and designed to protect the batteries and maintain a hermetic seal even in the rubber/aluminum, the nylon assembly was designed to meet the rigorous event of a severe crash. Special low/mid density SMC was developed for requirements of this application with regard to acoustics, crash, fatigue, and this application, saving an estimated 1.13 kg vs. standard SMC. The part also high-temperature stability. The result was a 50% weight savings, as well as features installed hardware seals, a reflective foil covering, and 73 openings to in-house production integration at the systems supplier, leading to further fasten the cover to the battery tray on this electric vehicle. reductions in logistics and transportation costs.

Engine Cradle Mount Highly Integrated Spare-Wheel Well 2011 Ford Motor Co. Ford Focus & C-Max Compact Cars 2010 Audi AG Audi A8 Luxury Sedan

System Supplier: Voestalpine Polynorm Group System Supplier: Hutchinson Paulstra Material Processor: Voestalpine Polynorm Group Material Processor: ThyssenKrupp Tallent Ltd. Material Supplier: Lanxess Material Supplier: DuPont Automotive Resin: Durethan BKV 60 H2.0 EF PA6 GF 60 Resin: Hytrel 7248 TEEE Tooling Supplier: Grupo Simoldes Tooling Supplier: SPLAST Sp z o.o This highly integrated, gas-assist, injection-molded spare-wheel well replaced In this application, an injection-molded TEEE thermoplastic elastomer steel and SMC with 60%-glass-reinforced PA 6 and an insert-molded aluminum replaced thermoset rubber thanks to the unique properties of the elastomer inlay and screw inserts. Despite the high glass loading levels, the resin offers and a post-mold forming step that used controlled insertion to achieve excellent flow and yields a part with very-good surface quality, while injection proper compression. This design also takes advantage of the elastomer’s molding brought significant parts-integration opportunities. The final part is ability to take a new material property set in order to meet hysteresis require- bonded into the body-in-white and therefore contributes to chassis stiffness, ments. Cost savings of 15% were achieved, and cycle time was reduced 90% reducing weight 30% (vs. steel) and capital equipment investment by 70%. It vs. thermoset rubber. is particularly well-suited for small-to-midsize production runs owing to this tooling savings.

L i f e t i m e A c h i e v e m e n t

SPE® TO BESTOW LIFETIME ACHIEVEMENT AWARD ON FORD RETIREE, ALLAN MURRAY AT 40TH INNOVATION AWARDS GALA

Allan D. Murray, Ph.D., who worked for more than 30 years at Ford Motor Co. as a manager of research, manufacturing, and product development guiding many advanced products and technologies to market, has been named the tenth recipient of the prestigious Lifetime Achievement Award from the SPE® Automotive Division. The award recognizes the technical achievements of automotive industry executives whose work – in research, design, and engineering, etc. – has led to significant integration of polymeric materials on vehicles.

When Dr. Allan Murray retired from Ford in 2001, he was the automaker’s technology director for the Partnership for a New Generation of Vehicles (PNGV), a government-industry initiative established to develop technology for affordable, fuel-effi- cient vehicles. In this position, which he held for about five years, he led teams of government and industry researchers who were working on a wide range of technologies, including advanced vehicle construction, powertrains, fuel cells, batteries, and power electronics. Prior to this, Murray was manager-Technology Strategy for Ford’s Plastic & Trim Products Division (PTPD), where he was responsible for identifying multimillion dollar efficiencies for the organization’s major products and manufacturing processes by benchmarking its manufacturing and engineering practices against leading competitors. Before this, Murray was manager-Advanced Technology Office, PTPD, where he led an innovative 40-person technical center in the development of leading-edge automotive plastic and composite products, processes, and methodologies.

In his previous position of manager-Exterior Systems R&D, Plastics Division, Murray applied plastics and composite technologies to achieve commercial success for bumpers, body panels, body structure, and vehicle lighting. It was in this position, starting in 1980, that Murray led the development of the first all-thermoplastic bumpers – from initial concept through production implementation – for Ford’s Escort, Aerostar, and Taurus/Sable passenger vehicles. Bumper revenues exceeded $300-million USD annually and the application garnered two Body Exterior awards in SPE’s Automotive Innovation Awards Competition. Subsequently, Murray also was instrumental in the development of the award-wining composite front-end structure on the 1996 Taurus sedan. Before holding this position, he was R&D department manager, Ford Vinyl Plant, where he oversaw development and production implementation of numerous new products and processes.

Murray began his Ford career in 1970 as a senior research scientist in the Polymer Science Division of Ford Motor Research Staff where he initiated development of thermoplastic stamping with the Metal Stamping Division and Body Engineering. This development was continued by Murray at the newly formed Ford Plastics Development Center in 1972, leading to its implementation at the Ford Maumee Stamping Plant. The first automotive thermoplastic stamping process, it allowed parts such as fender liners to be produced far faster (10-second cycle times) than with compression molding or thermoforming, and to do so in

20 L i f e t i m e A c h i e v e m e n t Award

thinner walls and at lower cost (30%) than the injection molded parts it replaced. Processing was done using matched metal dies mounted in metal “crank-type” stamping presses and the process remained in use for more than 20 years. In fact, the process was named the Grand Award winner in the SPE Automotive Innovation Awards Competition in 1976.

During his Ford years, Murray was a frequent university recruiter for the automaker and he mentored numerous recent university-graduate employees, helping guide and develop their careers. He served as chairman and president of the non-profit Michigan Materials and Processes Institute (MMPI), which sponsored collaborative university-industry materials research. Under his leadership, MMPI successfully merged with the National Center for Manufacturing Sciences.

Dr. Murray holds a Ph.D. in Metallurgical Engineering and Materials Science from Carnegie Mellon University, an MBA from Wayne State University, and a B.S. degree in Metallurgical Engineering from University of British Columbia. He is a long-time member of both SAE International and SPE. He holds two U.S. patents and he has written many technical papers for industry publication and chapters for handbooks, as well as given presentations at conferences worldwide.

Since retiring from the automaker, Murray has kept busy as a judge for the Premier Automotive Supplier Award for Creative Excellence (PACE), an annual innovation awards competition presented to global automotive suppliers for outstanding innovative developments. He has also participated as a technical expert on several U.S. National Academy of Science (NAS) committees to determine the prospective benefits of advanced vehicle technologies, and also on an NAS committee to rank and select technology proposals for funding.

Additionally, Murray has used his technical expertise as a consultant for Oak Ridge National Laboratory (ORNL) and Pacific Northwest National Laboratory (PNNL) on commercialization of technologies for industrial applications. He also has consulted with several businesses on the development and marketing of advanced technologies. In fact, on behalf of one client, he coordinated a Small Business Innovative Research (SBIR) funding grant application with the U.S. Department of Defense (DOD), obtaining Phase I and Phase II SBIR funding, and ensuring the project was completed successfully.

Currently, Murray is chief technology officer for Allied Composite Technologies LLC, a startup company developing and commercializing proprietary thermoplastic composites technologies for the automotive, alternative-energy, and building & construction industries.

Allan Murray has a long history of service to SPE. He joined the international engineering society in 1972 and has been a member of the Automotive Division board since the mid-1970s where he has held numerous positions, including member or chair of various subcommittees, division treasurer, division chair, and national councilor. He was elected to the prestigious Director Emeritus position 10 years ago and was also named an Automotive Division Honored Service Member and a Detroit Section Iron Man. In fact, Murray was the first automotive engineer to be elected a Fellow of SPE.

2010 SPE Automotive Innovation Awards Competition & Gala

2010 SPE Automotive Innovation Awards Competition & Gala M a t e r i a l s

LED Headlamp Reflectors Turbo Charge Air-Duct Resonator 2010 Hyundai Motor Co. Hyundai Equus Luxury Sedan 2010 Daimler AG Daimler Sprinter Commercial Van

System Supplier: SL Lighting Inc. System Supplier: Woco Group Material Processor: SL Lighting Inc. Material Processor: Not Available Material Supplier: SABIC Innovative Plastics Material Supplier: DSM Engineering Plastics Resin: Ultem Resin AUT200 Polyetherimide Resin: Stanyl Diablo OCD2100 Polyamide 46 Tooling Supplier: Not Available Tooling Supplier: Not Available High-temperature, lightweight PEI resin has replaced lacquered glass-rein- A new injection-molded PA 4/6 resin offering good weldability and excellent forced BMC and PPS, or die-cast aluminum in this LED headlamp reflector. long-term heat aging and mechanical-property retention to 220C proved ideal High-polish SPI-1 finish on hardened-steel tooling was required to achieve for meeting relevant requirements in this turbo charge air-duct resonator. the reflector’s highly polished surface, and the resin was formulated with a Replacing metal, the application reduced mass by 50% and cost by 20%. high-purity pigment package and low-oligomer base resin. The part saves approximately 50% weight and 30% direct costs vs. BMC, and an additional 10% indirect cost savings due to scrap reduction and recyclability.

On-Engine Oil Filter Module Seamless PAB IP Topper 2010 Chrysler Group LLC Chrysler Pentastar Engines 2011 Ford Motor Co. Lincoln MKX CUV

System Supplier: Hengst of North America Material Processor: Hengst of North America System Supplier: Automotive Components Holdings Material Supplier: BASF Corp. Material Processor: Leon Plastics Inc. Resin: Ultramid A3WG7 HRX BK PA66, 35% glass Material Supplier: Canadian General Tower Hydrolysis Resistance Resin: EuroMatt M2F186A2 PVC Tooling Supplier: VHM Tooling Supplier: Leon Plastics Inc. This material is a hydrolysis-resistant PA 6/6 modified during polymerization to This seamless passenger-airbag IP topper molded from vinyl provides a cost- increase hot glycol resistance at temperatures from 120-130C and to extend effective alternative to more costly leather and synthetic-leather materials hot-air heat-aging performance. It also offers reduced swelling and improved made from urethane while providing upscale aesthetics. A special topcoat weld strength in this application that is subject to oil and coolant contact. is used to provide a low-squeak finish and to improve mar resistance. Like Because of the material’s higher heat and chemical resistance, it allowed this previous materials, cut & sew stitching and hand wrapping via a bladder press oil-filter module to be mounted directly in the engine valley, eliminating 148 (for bonding) are used to join cover material to substrate. No tooling changes parts, reducing weight 43%, and saving over 60% direct costs, plus indirect were required. costs owing to greater reliability.

24 2010 SPE Automotive Innovation Awards Competition & Gala M a t e r i a l s

Reactor-Grade Talc-Filled Polypropylene Mold-in-Color ABS / PA Material for Defroster Grill 2011 Ford Motor Co. Ford Explorer SUV 2011 Ford Motor Co. Ford Mustang Sports Car

System Supplier: NYX Inc. System Supplier: Automotive Components Holdings Material Processor: NYX Inc. Material Processor: ACH - Saline Plastics Plant Material Supplier: Flint Hills Resources Material Supplier: BASF Corp. Resin: AP3320-HT 0 Reactor Grade Talc Filled PP Resin: Terblend NG02 ABS-PA Tooling Supplier: Toolplas Systems Inc. Tooling Supplier: Roush Industries In an industry first, reactor-grade, talc-filled PP was used to increase stiffness This molded-in-color ABS/PA material for a defroster grille uses special in a quarter trim panel while allowing a decrease in wallstock and improve- high-flow resin to eliminate knitlines, eliminating the need to paint this Class A ments in craftsmanship. By eliminating the burden of secondary compound- surface as had previously been required when the part was molded in PC/ABS. ing, a lower carbon footprint was achieved and the supplier gained greater Owing to the resin’s flow properties, clamp tonnage and injection pressures lot-to-lot consistency, higher stiffness that allowed for thinner parts to be were also reduced, helping save energy. The low-gloss injection-molded part molded (reducing mass 7%), and saving an estimated $500,000 annually over offers excellent heat resistance and durability and was dropped into previous precompounded PP grades. PC/ABS tooling without modifications. The result was approximately a $1.00 USD/vehicle direct cost savings.

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Low-Gloss Soft-Feel Resin 2011 Ford Motor Co. Ford Edge & Lincoln MKX CUV

System Supplier: Johnson Controls Inc. Material Processor: Johnson Controls Inc. Material Supplier: LyondellBasell Resin: Softell TKG259N Engineered Polyolefin Tooling Supplier: Toolplas Systems Inc. A new low-gloss, soft-touch TPO resin was developed for these applications, offering improved aesthetics, better haptics, and greater durability. Previously, to achieve this combination of properties, more costly wrapping or painting of the substrate was required. The new applications, the first in North America, led to cost reductions of $4 USD/part vs. painted and $5 USD/part vs. wrapped substrates.

Ni-MH Battery Cell Enclosure 2010 BMW AG BMW X6 ActiveHybrid CUV

System Supplier: Cobasys LLC Material Processor: PM Plastics Co. Material Supplier: AsahiKasei Plastics Resin: Xyron EV-103 PPE + PP Tooling Supplier: Arlen Tool Co. Ltd. This is the first use of engine coolant as a cell-cooling medium for Ni-MH battery cells for a hybrid cross-over utility vehicle. A special PPE/PP copolymer provides lightweight stiffness and creep resistance, plus seals out moisture for this battery-cell enclosure while providing resistance to alkali battery and coolant chemicals. The high-productivity resin provided excellent molding productivity in thin walls. A special film-insert molding process and secondary welding technology also were developed for this application. The unit saves an estimated 2.3 kg of weight vs. alternative resins considered for the application.

26 2010 SPE Automotive Innovation Awards Competition & Gala M a t e r i a l s

Turbocharged Engine Cover 2010 General Motors Co. Ecotec 2L Turbo for Cadillac CTS Sport Sedan

System Supplier: Camoplast Inc. Material Processor: Camoplast Inc. Material Supplier: DuPont Automotive Resin: Zytel PLUS PLS 95G35DH PA copolymer - extended HS Tooling Supplier: Camoplast Inc. This injection-molded turbocharged engine cover features a PA copolymer with new “Shield” technology for high-heat stability while doubling the heat-aging property retention vs. conventional nylons and some higher cost specialty resins. The material handles the application’s routine 180C service temperature and periodic 200C temperature excursions while offering easy processing, good surface finish, faster cycle times, and extended performance at up to 30% lower cost than specialty resins in this demanding underhood application.

Radio Bezel with MIC Piano Black 2010 Volkswagen AG Volkswagen Jetta Sedan

System Supplier: Visteon Corp. Material Processor: Huizhou Huayi Plastic Products Co., Ltd. Material Supplier: SABIC Innovative Plastics Resin: Lexan DMX1435 Polycarbonate Tooling Supplier: Not Available A new grade of polycarbonate with improved scratch resistance, and rapid heating and cooling of the tool were key to achieving molded-in-color “piano black” for this injection-molded switch bezel, which was produced without need for a base coat or clear coat. Since paint was eliminated, not only was $2.00 USD / vehicle saved, but VOCs and related waste were reduced during production, making the application “greener.”

2010 SPE Automotive Innovation Awards Competition & Gala Environmental

Recycled Polyol for Seat Foam Bio-Based TPU over Recycled ABS Tambour Door 2011 Chrysler Group LLC Jeep Grand Cherokee SUV 2011 Ford Motor Co. Lincoln MKZ Luxury Sedan

System Supplier: Magna Seating of America Material Processor: MS Chemical Techologies (Magna) System Supplier: International Automotive Components Material Supplier: InfiChem Polymers LLC Material Processor: Leon Plastics Inc. Resin: InfiGreen 320 0 Aromatic polyether polyols Material Supplier: Merquinsa & ACI Auto Group Tooling Supplier: Not Available Resin: Pearlthane ECO and Recycled ABS ECO 12T90 and This is the first industrial production application of flexible urethane seat 3000 Thermoplastic Urethane & ABS foams produced with polyols manufactured from post-industrial scrap foam. Tooling Supplier: Not Available A two-stage, closed-loop recycling process converts the scrap foam back into This is the auto industry’s first use of a bio-based TPU, which was injection a polyol product, resulting in zero waste going to the landfill and allowing up overmolded on top of a PC / ABS derived from 100% post-industrial scrap. to 10% recycled content in new parts. A unique process to reformulate the Both materials were a drop-in replacement on the tambour door. While reclaimed polyol to meet OEM specs was also developed for this application. weight was the same, a direct cost savings of $0.41 / part was achieved while Neither weight nor direct cost were negatively impacted and an estimated making the application both more environmentally friendly and ensuring $348,000 USD indirect cost savings was achieved, along with reduced CO 2 100% recyclability at end of part life. and landfilling.

Recycled PC / ABS Finish Panel Lumbar Seat-Adjuster Comfort Map 2010 Ford Motor Co. Ford Taurus Sedan 2011 Chrysler Group LLC Jeep Grand Cherokee SUV

System Supplier: Automotive Components Holdings System Supplier: Brose North America Material Processor: Summit Polymers, Inc. Material Processor: Axiom Products Material Supplier: Enviroplas, Inc. Material Supplier: AsahiKasei Plastics Resin: PC / ABS Resin: Tenac-C Z4520 Acetal Copolymer (POM) Tooling Supplier: Not Available Tooling Supplier: Not Available This A-surface finish panel is comprised of 100% recycled PC / ABS, which Low-VOC acetal copolymer was used for this structural / frictional component, delivers properties comparable to virgin resin yet saves $0.50 USD / lb. The reducing cabin odor / fogging for improved passenger comfort. Conventional part is injection molded and can be painted, filmed, or use molded-in-color. resins did not meet the new VDA 275 performance targets for low VOCs.

V e h i c l e E n g i n e e r i n g T e a m FORD MOTOR CO. RACKS UP THIRD SPE® VEHICLE ENGINEERING TEAM AWARD WIN WITH 2011MY EXPLORER® SUV

Ford Motor Co. is the 2010 winner of the SPE Automotive Division’s Vehicle Engineering Team Award (VETA) for significant use of innovative plastics content on the 2011MY Ford® Explorer mid-size sport-utility vehicle (SUV). This is the third year the automaker has been awarded the prize, winning last year with the 2010MY Ford® Taurus sedan and the previous year with the 2009MY Ford Flex cross-over-utility vehicle (CUV).

Unlike other SPE executive awards, the Vehicle Engineering Team Award recognizes the technical achievements of entire teams comprised of automotive designers and engineers, tier integrators, materials suppliers, toolmakers, and others whose work – in research, design, engineering, and/or manufacturing – has led to significant integration of polymeric materials on a notable vehicle. This is the fourth time the award has been given. The first winner was Porsche AG in 2004 for the ‘04MY Porsche® Carrera GT supercar.

Ford describes its newly redesigned Explorer vehicle as “defining the SUV for the 21st Century” and says it provides class-leading fuel economy (comparable to that of mid-size sedans), industry-leading safety features such as the world’s first rear inflatable seatbelts, integrated communications services like SYNC™ and MyFord Touch™, and quality that sets the benchmark in the SUV segment. With over 6-million units sold since the model was launched in 1990, the Explorer is the world’s best-selling mid-size SUV. In its newest form, it is lighter, offers best-in-class fuel economy and the lowest CO2 emissions of mid-size SUVs, plus makes extensive use of sustainable materials in keeping with the company’s focus on green technologies.

With numerous patents already filed on features that either debuted or were redesigned for the Explorer facelift, the vehicle makes extensive use of polymeric materials to improve fit and finish, reduce weight, and increase customer comfort and safety. In addition to winning the 2010 VETA award, seven components from the Explorer SUV were entered into the parts portion of SPE’s Automotive Innovation Awards Competition, with four nominations achieving Finalist status:

Body Interior: • Inside Handle/Tweeter/Bezel Wrap-Around – this wraparound inside door handle bezel with integral speaker tweeter and lock/ unlock switch provides outstanding fit & finish and function, • Interior Trim with 3-D Appearance – decorative film over a textured surface creates a 3-D appearance on door appliqués, while reducing cost and increasing design flexibility; u Materials: • Reactor-Grade, Talc-Filled Polypropylene (PP) – eliminating secondary compounding and reducing the carbon footprint of the manufacturing process, reactor-grade PP is used to mold quarter trim panels in the rear cargo area while improving craftsmanship and lowering cost; u Performance & Customization: • Dual-Lens Cup-Holder Light – a new one-piece design that integrate primary illumination surface with show-surface lens on cup-holder light rings improves perceived quality and enables vehicle occupants to customize interior lighting colors; u

2010 SPE Automotive Innovation Awards Competition & Gala

32 e h i c l e E n g i n e e r i n g T e Awarda m

Safety: • 4-way Adjustable EPP Headrest – a unique 2-piece EPP foam design allows for more comfortable, 4-way adjustable headrests that still comply with new safety requirements for rear impact conditions while facilitating assembly, reducing weight, and saving on tooling costs, • Inflatable Seatbelts – special tubular webbing used in the shoulder portion of rear seatbelts hides an inflatable airbag that is deployed when front driver and passenger airbags are triggered, protecting second- and third-row occupants, and particularly upper- and lower-percentage occupants, u • Advanced, All-TPO Airbag Chute for Seamless Passenger Airbag Systems – unique tool design allows a special “hook and window” feature to be created at the hinges of this advanced all-thermoplastic polyolefin (TPO) passenger-airbag chute, reducing squeak and rattle, improving airbag-to-chute alignment, reducing weight and cost, and making the entire assembly fully recyclable. u

Other plastics intensive features on the vehicle include all TPV glass runs, molded-in-color metallic sparkle silver roof-rack end caps, structural composite radiator support, all-plastic lower intake manifold, illuminated nameplate, and direct LED forward and side lighting.

u = Category Finalist

33 2010 SPE Automotive Innovation Awards Competition & Gala Performance & Customization

Fixed-Glass Roof Airy Feel Customizable Ignition Key System 2010 Ford Motor Co. Ford Mustang Sports Car 2010 Ford Motor Co. Ford Focus Compact Car

System Supplier: Pittsburgh Glass Works LLC System Supplier: Huf North America Automotive Parts Manufacturing Corp. Material Processor: Sekisui Chemical Co., Ltd. Material Processor: Huf North America Automotive Parts Manufacturing Corp. Material Supplier: Not Available Material Supplier: Not Available Resin: Not Available Resin: Not Available Tooling Supplier: Not Available Tooling Supplier: Not Available This large (1.2-m2) fixed-glass roof is the largest in the industry and features Offering new levels of control for parents, this ignition key system features an an acoustic PVB inner layer (ply) that provides a light, airy feeling in the vehicle embedded transponder that IDs the vehicle and allows parents to manage interior while increasing consumer comfort by reducing noise and glare, and functions like maximum driving speed when the vehicle is being operated eliminating the cost of tempered glass. by young drivers. All programming is managed from the master key via radio signals sent to other keys in the system. Radio waves travel between RF-transparent, injection-molded, ultrasonic-welded acetal resin housings on all keys in the system. New levels of safety are achieved while saving an estimated $200,000 USD in direct and $100,000 USD indirect costs annually.

Modular Sunvisor Storage System 2012 Ford Motor Co. Ford Mustang Sports Car

System Supplier: Irvin Automotive Products, Inc. Material Processor: Fortis Plastics LLC Material Supplier: Ticona Engineering Polymers Resin: Celcon UV90Z Acetal Tooling Supplier: Yusei Holdings This modular sunvisor-based storage system functions as a low-cost alternative to an overhead console to allow customers to customize storage for sunglasses, garage-door openers, coin or CD holders, organizers for pen and notepad, as well as cell phones. Interchangeable components injection molded from POM snap in and lock onto the base on the sunvisor, making changeover quick and easy.

34 2010 SPE Automotive Innovation Awards Competition & Gala Performance & Customization

Chrome-Film Thermoformed Bumpers 2009 Retro USA Limited Edition “Bullit” Mustang Sports Car

System Supplier: Retro USA Material Processor: Orion Plastics Inc. Material Supplier: Mytex Polymers Inc. / Soliant LLC Resin: MetaForm 7200 TPO Tooling Supplier: Castek This is the largest and thinnest chrome-film thermoformed TPO fascia to date. It offers excellent impact resistance and gravelometer performance, is fully recyclable, and offers a lustrous chromed surface while eliminating hexava- lent-chromium chemicals. The result is a lighter, less costly bumper cover that is more environmentally benign. Low tooling costs make this technology very attractive for quick-change transition parts at any production volume.

Dual-Lens Cupholder Light 2011 Ford Motor Co. Ford Explorer SUV

System Supplier: Chicago Miniature Lighting, LLC Material Processor: Chicago Miniature Lighting, LLC Material Supplier: Not Available Resin: Not Available Tooling Supplier: Global Management & Sales Group In this next-generation interior-lighting application, a 1-piece design integrates primary illumination surface and show-surface lenses for improved craftsmanship, 10% weight savings, and $0.35 USD cost savings vs. previous 2-piece lens designs. The design also reduced assembly costs and lowered warranty issues.

2010 SPE Automotive Innovation Awards Competition & Gala S a f e t y

PET Side-Curtain Airbag Film for Vacuum-Folded Airbag Application 2010 Ford Motor Co. Ford Escape SUV 2010 Ferrari 458 Italia Supercar

System Supplier: TRW Safety Systems System Supplier: Takata Corp. Material Processor: GST Material Processor: Takata Corp. Material Supplier: Hailide Co. Ltd. Material Supplier: Bemis / Schreiner Resin: Polyester CAS-Nr. [25038-59-9] PET Resin: ICE-F H 225 Co-extruded laminated film Tooling Supplier: Not Available Tooling Supplier: Takata Corp. This is the first production application of PET fabric for side-curtain airbags in To meet styling trends for smaller airbag cushion package space without the North American market, replacing nylon 6,6 yarns. The application makes loss of functionality, a packaging process common in the food and phar- use of unique PET yarns with spin finish and sizing. maceutical industries – vacuum-sealed films – has been applied to automotive safety restraints for the first time. New tool design and manufacturing equipment were required to produce the co-extruded, laminated vacuum- sealed pouches in order to meet airbag performance requirements and environmental durability for the life of the vehicle. Additionally airbag module mass was reduced by 15-30% and package size was greatly reduced.

Inflatable Seatbelts 2011 Ford Motor Co. Ford Explorer SUV

System Supplier: Key Safety Systems Material Processor: Not Available Material Supplier: Not Available Resin: Not Available Tooling Supplier: Not Available Special tubular webbing used in the shoulder portion of rear seatbelts hides an inflatable airbag that is triggered when front driver and passenger airbags are triggered, protecting second- and third-row occupants, and particularly upper- and lower-percentage occupants. During inflation, the airbag breaks through the tubular webbing, expanding across the chest area, and a special coating helps the airbag stay inflated for 6 sec. to protect for multiple crash modes. A new weaving technique was used to form the tubular webbing and a frangible edge that allows the belt to split and the airbag to deploy.

38 2010 SPE Automotive Innovation Awards Competition & Gala S a f e t y

Energy-Absorbing Module 2010 General Motors Co. Chevrolet Silverado Pickup, Suburban, Tahoe & Avalanche SUVs, GMC Sierra Pickup & Yukon SUV, and Cadillac Escalade Luxury SUV

System Supplier: International Automotive Components Material Processor: International Automotive Components Material Supplier: LyondellBasell & Formosa Plastics Resin: Pro-fax, Grade: SG802N (LB) and Formelene (Formosa Grade: 6535N) SG802N High-Crystalline Polypropylene Tooling Supplier: International Automotive Components The injection-molded Safe-TEC module’s design flexibility provides a unique safety-integration point, since stiffness can be tuned multi-axially to optimize energy-absorption requirements for occupants ranging from 5th to 50th per- centile – all in a single component. The module’s design can be integrated with existing injection-molded components to reduce weight, investment, and complexity and to significantly reduce part count. Mass was reduced 0.91 kg / vehicle and significant cost-savings were achieved. The pelvic version saves $3.20 USD for pickups and $2.77 USD for SUVs, while the armrest version saves $3.30-$3.50 USD / vehicle.

Advanced Passenger Airbag Chute 4-Way Adjustable EPP Headrest 2011 Ford Motor Co. Lincoln MKX CUV 2011 Ford Motor Co. Ford Explorer SUV

System Supplier: Automotive Components Holdings System Supplier: Windsor Machine Group Material Processor: Automotive Components Holdings Material Processor: Tegrant Corp. Material Supplier: Mitsubishi Chemical USA Inc. Material Supplier: JSP Resin: Thermorun TT850B TPO Resin: Arpro EPP Tooling Supplier: Not Available Tooling Supplier: Tegrant Corp. A unique cavity / core tool design at the hinges allowed a special “hook and A unique 2-piece EPP foam design allows for more comfortable, 4-way window” feature to be created on this advanced passenger-airbag chute adjustable headrests that still comply with new safety requirements for rear that intersects the chute’s inner wall rather than the top flange. The result impact conditions. Snapping into a metal assembly, a common rear EPP part is reduced squeak and rattle, vertical support, and better PAB-to-chute mates with program-specific EPP front part to aid in bonding / assembly with alignment, as well as a savings of 612 g and $4.36 USD / vehicle. minimal new tooling investment, while also lowering weight.

39 H all o f F a m e

‘85MY CHEVROLET® CAVALIIER® NAMED 2010 HALL OF FAME WINNER IN SPE® AUTO INNOVATION AWARDS COMPETITION

The 1985MY Chevrolet® Cavalier® sedan from then General Motors Corp. (GM) — the first vehicle to use front and rear thermoplastic polyolefin (TPO) bumper fascias — was selected by the Automotive Division of the Society of Plastics Engineers (SPE®) as the 2010 Hall of Fame winner of the group’s 40th-annual Automotive Innovation Awards Competition. Automotive plastic parts considered for the Hall of Fame award must have been in continuous service in some form for at least 15 years and preferably have been widely adapted within the automotive or ground transportation industries.

“This application has been so successful,” said Nippani Rao, president, Rao Associates and co-chair of the 2010 SPE Automotive Innovation Awards Hall of Fame search committee, “that even after 25 years, 90% of all the cars I see when I’m driving have TPO fascias.” The application not only proliferated throughout North American vehicle production, but also was heavily adapted in Europe and Asia. In fact, today an estimated 65-70-million vehicles each year are equipped with TPO fascias. Assuming a typical set of these parts on front and rear bumpers weigh a total of 14- pounds / 6.4 kilograms, this single application still consumes close to 1-billion pounds / 453,592 metric tons of TPO polymers annually worldwide.

Hifax® ETA3041 TPO reactor resin supplied by LyondellBasell predecessor company, Himont was used in the first injection- molded TPO fascias to replace reaction-injection-molded (RIM) polyurethane. The switch from urethane to olefin materials brought a number of significant benefits, including faster processing cycles, lower processing costs, lower part weight (10-15% lighter), better weatherability, and improved low-temperature impact strength/ductility. Environmental benefits of the application were weight reduction (10-15%) and the ability to reprocess (recycle) in-plant scrap as well as post-consumer parts at end of vehicle life.

Additionally, the injection-molding process and its ability to use a lot of tooling action led to greater design flexibility, facilitating the use of deep draws and undercuts in part designs, allowing more sculpted vehicle styling lines, and providing the opportunity to consolidate parts and mold-in attachment and structural features. Initially, the TPO fascias were painted to match body panels, but later featured contrasting molded-in-color – typically black or gray. Buckeye Plastics/Worthington was the original systems supplier/molder for this application.

40 all o f F a m e

‘85MY CHEVROLET® CAVALIIER® NAMED 2010 HALL OF FAME WINNER IN SPE® AUTO INNOVATION AWARDS COMPETITION 2010 SPE Automotive Innovation Awards Competition & Gala Process / Assembly / Enabling Technologies

Integrated Sunroof Module Cam Cover with Integrated Variable-Valve Timing 2010 General Motors Co. Cadillac CTS Sport Sedan 2011 Chrysler Group LLC Jeep Cherokee SUV

System Supplier: Inalfa Roof Systems Group B.V. System Supplier: Bruss NA Material Processor: NS Technologies Group Material Processor: Bruss NA Material Supplier: AsahiKasei Plastics Material Supplier: BASF Corp. Resin: Thermylene P7-45FG-0790 BK711 45% GR-PP Resin: Ultramid A3WG7 HP BK20560 PA66 35% glass, Tooling Supplier: Datrin Industry Co. Ltd. high productivity Tooling Supplier: Active Burgess This 12-meter part is the first integrated sunroof-module assembly using 45%-glass reinforced PP and replacing long-glass PP and short-glass ASA / PBT This is the first time that a plastic surface has been used for a cam variable- while meeting OEM requirements. Its novel design consolidates 4 parts into 1 valve timing cover. Holding a positional tolerance of 0.5 mm and required (front and rear beam and 2 guides) to reduce assembly time and weight (12%) to pass 100% inspection, the application required development of a special thanks to injection molding via the Mucell process. Other benefits include 24% workstation with laser and optical measurement tools to verify dimensional component cost, and 47% capital-investment cost savings. compliance. High-flow, 35%-glass-reinforced PA 6/6 was injection molded for this application and replaced machined die-cast aluminum while saving 2,200 g and 25% direct material costs.

High-Gloss Finish without Paint 2011 Ford Motor Co. Ford Escape SUV

System Supplier: Summit Polymers, Inc. Material Processor: Summit Polymers, Inc. Material Supplier: SAMSUNG Cheil Industries, Inc. Resin: PC & ABS Tooling Supplier: Namdo Tool Co. These are the first molded-in-color, high-gloss, jet-black ABS instrument panel, console, and door-finish panel applications produced by a modified injection process that eliminates paint while avoiding molding defects such as flow marks and knitlines. By increasing the cavity-side tool temperature to between 110 and 160C, before and during injection, then quickly cooling down before the part is injected, a highly aesthetic surface is achieved. A new grade of ABS resin was developed to deliver deep, jet-black color while also meeting head-impact criteria. The application increased aesthetics, eliminated paint, improve environmental compatibility, and lowered direct costs by 20-65%.

2010 SPE Automotive Innovation Awards Competition & Gala Process / Assembly / Enabling Technologies

Spoiler Pan in Liftgate 2010 Porsche AG Porsche Panamera Luxury Sedan

System Supplier: VW Braunschweig Material Processor: VW Braunschweig Material Supplier: SABIC Innovative Plastics Resin: NORYL GTX975 PPO / PA Tooling Supplier: Schweiger Formenbau This is the first online-painted liftgate / spoiler module in plastics, which resulted in high levels of functional integration, as well as cost and weight reduction. The injection-molded part replaced a 6-piece aluminum assembly. Maintaining the same process flow at the OEM, the high-heat, conductive part is assembled to the body-in-white where it passes through eCoat and paint. An estimated 1.5 kg of weight and 20% direct costs were saved, along with indirect costs by lowering tooling investment and eliminating bonding / sealing as was done with the aluminum part.

Multi-Functional Exchange Blow Molding Air Duct Glueless Sonic Edge-Wrapping Process 2010 Subaru Suburu Legacy Sedan & Outback CUV 2011 Ford Motor Co. Lincoln MKS Luxury Car

System Supplier: Excell USA Inc. System Supplier: Dakkota Integrated Systems Material Processor: Excell USA Inc. Material Processor: Dakkota Integrated Systems Material Supplier: Channel Prime Alliance & ExxonMobil Chemical Material Supplier: Not Available Resin: Marlex / Santoprene AMN-010 / 101-73 Resin: Not Available Polypropylene / TPV Tooling Supplier: Not Available Tooling Supplier: Excell Corporation To achieve a quality edge-wrapped finish around injection-molded moon-roof This multi-functional-exchange blow-molded air duct integrates the resonator, reinforcement rings on this thermoformed headliner without the cost and brackets, and pipe in a single step using a combination of hard HDPE and soft mess of adhesives, the textile material was sonically welded to the reinforcing- TPV resins via a new process. The part replaced a combination of rubber hose, ring polymer. Special tooling was created for this application, combining metal and resin ducts, the resonator, and clamps with a single part produced a traditional edge-wrap that allowed sonic welding. The new process saved in a single process step where material change, wall thicknesses, and inner 91 g / headliner and $5 USD direct cost by eliminating glue. pressure are all controlled very precisely. The application saved an estimated 30-40% in weight and 25-35% in both direct and indirect costs.

44 2010 SPE Automotive Innovation Awards Competition & Gala P o w e r t r a i n

Diesel-Exhaust Fluid (DEF) System Electronic Throttle-Control Actuator 2011 Ford Motor Co. Superduty Diesel Pickup 2010 General Motors Co. All (Global)

System Supplier: Robert Bosch LLC Material Processor: Kautex Textron GmbH & Co. KG System Supplier: Continental Automotive Material Supplier: Multiple Material Processor: Multiple Resin: Multiple Material Supplier: DSM Engineering Plastics Tooling Supplier: Multiple Resin: Stanyl / Arnite TW278F10, TZ6280, TW241F10, TW271B3, TW241F12, TW200B6 and TV4230 This is the first high-volume pickup truck application to use an all-plastic system to fill, store, and deliver diesel-exhaust fluid (DEF) to the exhaust system to Polyamide 46 and PBT meet stringent diesel-emissions requirements. Multiple materials and molding Tooling Supplier: Not Available processes are featured on this system, 90% of whose components are polymeric, This electronic throttle-control actuator meets or exceeds all USCAR global including the plastic filler-pipe assembly (which requires no clamps), plastic standards and focused on mass reduction. The unit makes use of injection- supply module with integrated pump, reverting valve, pressure sensor, heater, molded PA 4/6 and PBT resins to produce 7 innovative plastic components: and filtration unit. Additional plastic components in the system include heated an ultra-thin-wall carbon fiber-reinforced PA 4/6 bushing, ultra-high-strength intake reservoir (with integral heater), level sensor, filter, and temperature sensor. gears with outstanding dimensional stability, high-temperature electric motor The only other material that could have withstood the DEF fluid is stainless steel, brush card, and a uniquely designed cover / cap combination. In total, 43 g of which would have been 7x heavier and have cost 40% more. weight were saved on this program vs. previous designs.

45 2010 SPE Automotive Innovation Awards Competition & Gala P o w e r t r a i n

Stator Solenoid 2009 Scania-Cummins

System Supplier: SEM AB Material Processor: Liljas Plast AB Material Supplier: Ticona GmbH Resin: Vectra E130i LCP Tooling Supplier: Not Available This is the first time that an LCP has been used for a stator-solenoid application. The resin was chosen because of its ability to withstand high pressures, temperature to 180C, harsh chemicals, and due to its low CLTE. Fully automated injection molding with 3 metal inserts is used to produce the parts.

Impact Blocker for Fuel System Protection Thermoplastic Oil-Pan Module 2010 Chrysler Group LLC Jeep Wrangler Compact SUV 2010 Chrysler Group LLC 5.7L V8 Hemi Engines

System Supplier: MAHLE North America Material Processor: MAHLE North America System Supplier: VM Motori S.p.A. Material Supplier: BASF Corp. Material Processor: Premix Inc. Resin: Ultramid B3ZG7 OSI PA6, Impact-Modified 35% glass Material Supplier: Premix Inc. Tooling Supplier: Integrity Tool & Mould Inc. Resin: Premi-Glas 1286 Hybrid Vinylester & Polyester SMC A next-generation, all-plastic oil-pan module is specifically designed for this Tooling Supplier: Witco Tool & Die trail-rated vehicle to be able to channel oil uphill on a 60% grade. New levels This compression-molded, SMC part provides impact protection for a diesel- of parts integration have incorporated the pan’s windage tray with cam engine fuel pump. A new application for thermoset composites, it replaces scraper function, oil pickup tube, seal, fasteners, and oil plug in an injection- die-cast metal and nylon for a 50% weight savings (vs. metal) and a 50% cost molded assembly that is joined via vibration and infra-stake welding. The reduction. Compression-molded SMC brought short tooling lead times and 35%- glass-reinforced PA 6 base material was optimized for stone impact and excellent dimensional tolerances, plus impact strength that exceeded both retention of mechanicals when exposed to hot oil, cold temperatures, and metal and nylon. road salts. Replacing stamped steel, quiet steel, and cast aluminum, the all- plastic oil pan reduces weight 41%, saves 50% on tooling costs, and eliminates 4 assembly operations.

46 2010 SPE Automotive Innovation Awards Competition & Gala P o w e r t r a i n

Transmission Sump Filter 2009 General Motors Co. GM FWD Cars w/6-Speed Transmissions

System Supplier: Filtran Ltd. Material Processor: Not Available Material Supplier: Entec Polymers, LLC Resin: Hylon N1033HL blk & nat 003 Nylon 66 Tooling Supplier: Not Available This all-plastic assembly replaced crimped metal for a transmission sump filter. Laser welding was used to rapidly and efficiently join the injection-molded components so there was no debris that could contaminate the filter media as can occur with spin or sonic welding. The resin also allows for laser marking for easy traceability.

47 H all o f f a m e b y y e a r

The Hall of Fame Award is given annually for an application that has been in continuous use for 15 years or more, and has made a signficant and lasting contribution to the application of plastics in automobiles.

Year Recognized OEM Application Material 2009 General Motors Co. Thermoplastic Vertical Body Panel MPPE/PA 2008 Chrysler LLC Rear Seat Cushion PUR Foam 2007 Ford Motor Co. Radiator End Tank PA 6/6 2006 General Motors Corp. Thermoplastic Front Grille ABS 2005 Porsche Thermoplastic Intake Manifold PA 2004 Ford Motor Co. Box Beam Bumper PC/PBT 2003 General Motors Corp. Dual-Density Energy Absorbing Bumper System PP 2002 General Motors Corp. Mini-Wedge Latch and Door-Lock Actuator PA 2002 General Motors Corp. Wiper-System Transmission Housing PA 2001 General Motors Corp. Instrument-Panel Retainer SMA 2000 Volkswagon AG Fuel Tank HDPE 1999 Ford Motor Co. Hydraulic Clutch Actuator PA 1998 Citroën Fan Shroud PA 1997 Ford Motor Co. Transmission Seal PPS 1996 General Motors Corp. Front Fenders RIM-PUR 1995 General Motors Corp. Guide-Flex Energy Absorbers EVA 1994 Ford Motor Co. Headlamp Assembly PC 1993 General Motors Corp. Front/Rear Bumper Covers RIM-PUR 1992 General Motors Corp. Composite Exterior Body Panels SMC 1991 General Motors Corp. Tilt Steering-Wheel Centering Sphere Acetal 1990 General Motors Corp. Transverse Leaf Spring Epoxy 1989 American Motors Corp. Battery Case PP 1988 Ford Motor Co. Windshield Interlayer PVB 1987 General Motors Corp. Grill-Opening Panel SMC 1986 Chrysler Corp. Heater Housing PP 1985 Chrysler Corp. Disc-Brake Piston Phenolic 1984 General Motors Corp. Front-Fender Wheel Liner PP 1983 General Motors Corp. Emissions Control Canister PA

G r a n d A w a r d W i n n e r b y y e a r

Year OEM APPLICATION MATERIAL 2009 General Motors Co. Shielded Plastic Case Radio PC/ABS 2008 BMW Twin-Sheet Blow-Molded Fuel System HDPE 2007 General Motors Corp. Backlighting with Color-Converting Plastic PC 2006 DaimlerChrysler Blow-Molded Front- & Rear-Bumper System TPO 2005 Honda Motor Co. Composite In-Bed Trunk SMC 2004 Ford Motor Co. Door Trim with Integrated Acoustic PP Chamber and Subwoofer 2003 DaimlerChrysler Roof Module PC Copolymer 2002 DaimlerChrysler Extruded Polymer Film Fascia Multi-Layer Ionomer 2001 General Motors Corp. Nanocomposite TPO Nanocomposite TPO 2000 Ford Motor Co. Controlled Energy Management Bumper Isolator HDPE 1999 DaimlerChrysler Fan Shroud and Reservoir Assembly PP 1998 Mitsubishi Motors “I” Section Bumper Beam PP-GMT 1997 Ford Motor Co. “Carpet to Car Parts” PA 1996 General Motors Corp. Structural Battery Tray PP-GMT 1995 Ford Motor Co. Integrated Front-End System SMC 1994 General Motors Corp. Thermoplastic Air-Intake Manifold PA Copolymer 1993 Ford Motor Co. Front-Suspension Stabilizer Link POM 1992 Chrysler Corp. Instrument-Panel System PP-GMT, MPPE, PP & PU Foam 1991 Chrysler Corp. Integrated Child’s Seat and Top Impact Pad PP-GMT, Expanded MPPE 1990 General Motors Corp. Exterior Door Panel PC/ABS 1989 Chrysler Corp. Composite Wheel SMC/XMC 1988 General Motors Corp. Front Fender MPPE/PA 1987 General Motors Corp. Quarter-Panel Assembly – Sportside SMC 1986 General Motors Corp. Quarter Window PMMA 1985 General Motors Corp. Windshield with Anti-Lacerative Layer Polyvinyl Butyral/PE Film 1984 Ford Motor Co. Drive Shaft Vinylester/Graphite/Glass 1983 General Motors Corp. Exterior Body Panels SMC, RIM, RRIM, & TPO 1982 General Motors Corp. Tailgate Assembly SMC 1981 Ford Motor Co. Radiator-Core End Caps PA 1980 General Motors Corp. Rear-Axle Leaf Spring Epoxy 1979 Ford Motor Co. Grille-Opening Panel Assembly SMC 1978 General Motors Corp. Bucket-Seat Frame SMC 1977 Ford Motor Co. Instrument Panel 1976 Ford Motor Co. Fender Aprons PP 1975 American Motors Corp. One-Piece Jeep Top PC 1974 General Motors Corp. Fascia and Rear Bumper Cover RIM-PUR 1973 Ford Motor Co. Block-Heater Motor Housing 1972 General Motors Corp. Radiator Fan-Shroud Assembly PP 1971 Ford Motor Co. Transmission Reactor Phenolic

50 2010 SPE Automotive Innovation Awards Competition & Gala

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52 S o c i e t y o f P la s t i c s E n g i n e e r s Automotive Division

D i v i s i o n O f f i c e r s & E x e c u t i v e C o m m i t t e e CHAIR PAST-CHAIR DIVISION COUNCILOR Jeffrey Helms Maria Ciliberti Tom Pickett Ticona Engineering Polymers Ticona Engineering Polymers General Motors Co. CHAIR-ELECT TREASURER DIRECTORS EMERITUS Anthony Gasbarro Yvonne Bankowski Josh Madden Marubeni USA Ford Motor Co. Material Engineering Services VICE-CHAIR SECRETARY Allan Murray Gregg McDonald Monica Prokopyshen Allied Composite Technologies PolyOne Corp. Retired - Chrysler LLC Nippani Rao Rao Associates

C o m m i t t e e C h a i r p e r s o n s INNOVATION AWARDS PROGRAM MEMBERSHIP SOCIAL Jeffrey Helms Bill Pippine Ben Soltisz Ticona Engineering Polymers Takata Holdings LLC HOUSE ANTEC NEWSLETTER EDITOR Ed Garnham Tom Pickett Kevin Pageau ACCE, COMMUNICATIONS & WEB General Motors Co. Tegrant Corp. Peggy Malnati AutoEPCON NEWSLETTER SPONSORSHIP Malnati & Associates Norm Kakarala Teri Chouinard EDUCATION Inteva Products Intuit Group, LLC Monica Prokopyshen Nippani Rao GOLF OUTING Retired - Chrysler LLC Rao Associates Fred Deans Allied Composite Technologies

B o a r d o f D i r e c t o r s TO MAY 2011 TO MAY 2012 TO MAY 2013 Norm Kakarala Bonnie Bennyhoff Jane Aselage Inteva Products ExxonMobil Chemical Ford Motor Co. Mark Lapain Fred Deans Sheldon Brown Magna International Allied Composite Technologies Toyota Technical Center Kevin Pageau Ed Garnham Susan Cole Tegrant Group SPE Miller Cole LLC Nippani Rao Chuck Jarrett Mike Masserant Rao Associates SABIC Innovative Plastics Ford Motor Co. Jackie Rehkopf Peggy Malnati Ron Price Exponent Malnati & Associates Global Polymer Solutions Suresh Shah Jay Raisoni Dave Reed Delphi Corp. Adell Plastics David Reed Consulting LLC Johanne Wilson Mike Whitens BASF Ford Motor Co.

The SPE Automotive Innovation Awards Gala would not be possible without the gracious supportto of ourour sponsors, who Sponsors underwrite the cost of this event. SaluteHence, it is with great appreciation that we thank and acknowl- edge the contributions of the 2010 SPE Automotive Innovation Awards Gala sponsors and other patrons for making this show a success.

Gala &Ticona Afterglow Engineering Polymers Sponsor

AmericanGold Chemistry Sponsors Council – Plastics Division DuPont Automotive SAMSUNG Cheil Industries

AdvertisingChicago Miniature Only Lighting Sponsor LLC SilverLyondellBasell Sponsors Industries Kautex Textron GmbH & Co. KG Media / AssociationAutomotive Design & Production Sponsors Magazine Automotive Engineering Int’l. Magazine BronzeAdell Plastics Sponsors Inc. Automotive NewsWire AkzoNobel China Plastics & Rubber Journal AsahiKasei Plastics NA, Inc. China Plastics & Rubber Journal, Int’l. BASF Corp. Composites Technology Magazine Chevron Phillips Chemical Co. CompositesWorld.com Cooper-Standard Automotive High-Performance Composites Magazine DSM Engineering Plastics Journal of Automobile Engineering ExxonMobil Chemical Co. Plastics Engineering Magazine Inteva Products LLC Plastics Technology Magazine JSP Plaspec Global Plastics Selector Key Safety Systems Polymotive Magazine Plasan Carbon Composites Rubber World Magazine Röchling Automotive Soc. of Automotive Engineers (SAE) Int’l. SABIC Innovative Plastics Ward’s AutoWorld Magazine Tribar Manufacturing Ward’sAuto.com Visteon Corp.