Page 39 - Plastics News January 2022

FEATURE

out; and primer and paint are selectively Spring are Lear and HellermannTyton North
applied to the B side of the part—the This new hybrid rear leaf spring featured America. Material supplier/toolmaker
first use of paint-over-hardcoat for an on the 2021 Ford F150 combines a are DSM and HellermannTyton North
auto exterior-trim application. America.DSM’s Akulon RePurposed
nylon 6 is melt compounded and is said
Interior: Third-Row Seatback to provide performance comparable to
Another industry first is the replacement virgin prime resin at 10% cost savings,
of a 16-piece steel assembly with a lower energy use, improved supply-chain
single, shoot & ship plastic part for this stability, and LCA benefits. No tooling
third-row seatback in the 2021 Sienna changes and minimal process changes
Toyota. Tier supplier/processor are were needed for this drop-in substitution.
Toyota Boshoku Corp and Flex-N-Gate
Corp. BASF is the material supplier and Materials: Composite Roof Receiv-
Concours Technologies is the toolmaker. ers
Using BASF’s new Ultramid B3ZG7 high-strength steel main pack plus Six brackets
CR, a 35% short-glass, impact-modified an HP-RTM fiberglass-reinforced for removeable
nylon 6 injection grade, saved 30% in epoxy helper that reduces mass 30% hardtop and
while providing the same stiffness and softtop roofs
durability as a conventional steel leaf were converted
spring. Tier supplier/processor are fr om cast
Rassini Suspensiones and SGL Carbon, steel to 30%
and the materials suppliers are Hexion u lt ras hor t
and SGL Carbon. Additional benefits c arbon-
cited include increased payload capability, fiber (USCF)
lower part count, decreased interleaf reinforced PPA
friction, smoother engagement, lower for the 2021
noise, and lower carbon footprint. Stellantis Jeep
Wrangler and Jeep Gladiator. These
weight and 15% in cost. Moreover, this Environmental: Wiring-Harness
all-plastic, freestanding seatback offers Clip injection molded roof receivers provide
excellent energy absorption without need comparable part strength while reducing
for metal support brackets and is said costs 38% and weight 79%. The tier
to represent a two-fold improvement in supplier is Stellantis and the material
crash performance and takes 63% less supplier/toolmaker are Mitsubishi
effort for occupants to raise the seat to Chemical Advanced Materials and
its upright position, eliminating the need Maple Mold Technology. Mitsubishi’s
for a seat motor. KyronMAX S-4340 PPA with 30%
USCF allowed the elimination of powder
Chassis/Hardware/Grand Award coating, providing improved scratch and
Winner: Multi-Material Rear Leaf mar resistance and a weatherable Class
A finish that allowed for mid-program
These injection molded recycled nylon 6 replacement and backward service
wire-harness clips featured on the 2021 compatibility. The USCF composite
Ford Bronco Sport are injection molded is said to mold like neat polymers but
from 100% PCR ocean plastics. “Ghost outperforms long-fiber (LFT) materials,
gear” (discarded fishing nets) are collected is fully recyclable, and has a lower carbon
by fishermen in the Indian Ocean and footprint than metal/alloy parts. Direct-
Arabian Sea, providing jobs and healthier drop valve gates and T-nut fasteners also
marine life. Tier supplier/processor were key enablers.

38 PLASTICS NEWS JANUARY 2022 39 PLASTICS NEWS JANUARY 2022