| Description |
|
Negative Thermoformed TPO Instrument Panel |
| OEM, Model, Model Year |
|
Hyundai, Tiburon, 2002 |
| System Supplier, Contact, Phone |
|
Visteon Corporation, A Wisniewski, (734)429-6339 |
| Molder/Processor |
|
Visteon Korea |
| Toolmaker |
|
Kohnan Tokusyu Sangyo |
| Material Supplier |
|
Hanwha Corp. |
| Generic resin type |
|
TPO |
| OEM Engineer, Title and Phone |
|
Mr. Chae-Won Kim, VP of R&D, Hyundai Motor Co. , (734)747-6600 |
| Nominated by, Company |
|
Cheryl L. Moore, Visteon Corporation |
| Address |
|
5500 Auto Club Drive, Dearborn, MI 48126 |
| Phone |
|
(313)755-1036 |
| Fax |
|
(313)755-1375 |
| Email |
|
cmoore10@visteon.com |
| Summary | | The unique feature is craftsmanship. Distinct lettering, leather grain, technical grain reproduction usually found only in powder slush molding process is reproduced in the lower cost negative thermoforming with TPO skin materials. Multiple textures on the same covering, best in class seamless passenger air bag restraint systems, non PVC, removable inserts and logos can be thermoformed. Weight Savings: Over one pound vs TPU materials. Cost Savings: N/A Cost Avoidance: Reduced tooling cost, faster cycle times, removeable/interchangeable inserts. |
| Most Innovative Feature | | The unique feature is craftsmanship. Distinct lettering, leather grain, technical grain reproduction usually found only in powder slush molding process is reproduced in the lower cost negative thermoforming with TPO skin materials. |
| Other Innovative Features | | Multiple textures on the same covering, best in class seamless passenger air bag restraint systems, non PVC, removable inserts and logos can be thermoformed. |
| Forming Process | | Thermoforming |
| First time process used? | | This application is the first fully covered instrument panel to be done in female thermoforming. Half panels and small. flat, topper pads have been done previously. |
| Previous Process Used | | Pre-embossed (grained) TPO sheet has been used in male thermoforming of instrument panels. |
| Tooling Innovations | | Tooling is "porous nickel" for easy air flow in the thermoforming process. Electroplating process was developed to include vacuum holes in the nickel shell during the plating process rather than as an added operation afterwards. |
| New Material Developments | | Top coating of TPO sheet for gloss control and modified formulations of TPO sheet were developed. |
| Weight Savings | | TPO sheet reduces the in vehicle weight by over one pound as compared to TPU materials. |
| Direct Cost Savings | | Processing Time: Negative Thermoforming 60 seconds, Powder Slush Molding 210 seconds. Material Cost: TPO <<< TPU Slush Powder |
| Indirect Cost Savings | | Reduced tooling cost, reduced cycle times, removeable/interchangeable inserts. |
| Direct Consumer Benefit | | Improved craftsmanship, non PVC |
| Translates to other Vehicles? | | This application can be applied to any instrument panel which uses a covering. |
| Safety Benefits | | n/a |
| Environmental Benefits | | Reduces the use of PVC materials in vehicle interiors. |
| Additional Info | | Please see attached file: Attachment_Neg TPO_Submittal.doc |