| Description |
|
Structural Instrument Panel/Cockpit Module |
| OEM, Model, Model Year |
|
DaimlerChrysler, Jeep Liberty, 2002 |
| System Supplier, Contact, Phone |
|
Johnson Controls, Inc., Larry Cross, (616)394-8778 |
| Molder/Processor, Contact and Phone |
|
Intertec Systems, Andy Dargavell, (248)204-6500 |
| Toolmaker, Contact and Phone |
|
Paragon Die, Greg Eidenberger, (616)949-2220 |
| Material Supplier, Contact and Phone |
|
Dow Automotive, Scott Burr, (248)391-6300 |
| Generic resin type |
|
PC/ABS |
| Resin Trade Name |
|
Pulse |
| Grade |
|
2000 |
| OEM Engineer, Title and Phone |
|
Dale Gedeon, Engineering Supervisor, (810)995-7353 |
| Nominated by, Company |
|
Larry Cross, Johnson Controls, Inc |
| Address |
|
915 East 32nd Street, Holland, MI 49423 |
| Phone |
|
(616)394-8778 |
| Fax |
|
(616)394-2299 |
| Email |
|
larry.cross@jci.com |
| Summary | | The structural IP, consisting of the rear duct, front duct and first surface are vibration welded to create a single, lightweight , rigid structure that provides cross-car structure, airflow channels and energy management. This structure carries complete cockpit content, including HVAC and steering column through to final assembly. Supports RH-and-LH-Drive with 65% common components -- and 75% symmetrically opposite components. Weight Savings: 10% Cost Savings: 10% Cost Avoidance: Labor savings, material handling, line space, rework. |
| Most Innovative Feature | | The structural instrument panel, consisting of the rear duct, front duct and first surface are vibration welded to create a single, lightweight , rigid structure that provides cross-car structure, airflow channels and energy management. This structure carries complete cockpit content (HVAC, steering column, pedal assembly, air bag assembly, audio, IP and body wire harness, junction block) during manufacturing, transportation, and final assembly. |
| Other Innovative Features | | The structural IP supports RH-and-LH-Drive with 65% common components -- and 75% symmetrically opposite components. Molded-in center locator pin; molded-in wire channels; molded-in glovebox hinge for interchangeable glovebox door; packaged in a narrow space for a "command of road" feel; cowl side mounting brackets; reduced tolerance stackup; excellent fit and finish, NVH and BSR performance. |
| Forming Process | | Injection molding and vibration welding |
| First time process used? | | There have been injection molded IP structural ducts. However, this is first three part design (including the aesthetics first surface) that is vibration welded into a single system that carries complete cockpit content and is responsible for energy management. |
| Previous Process Used | | Cross-car structures are typically steel and to a lesser extent, magnesium. There are other examples of thermoplastic structural ducts, but not to this level of integration where complete cockpit content is built and shipped on the thermoplastic structure. |
| Tooling Innovations | | na |
| New Material Developments | | First use of a soft-touch paint with UV stabilizers on the first surface. |
| Weight Savings | | 10% reduction compared to the Jeep Cherokee. |
| Direct Cost Savings | | 10% reduction compared to the Jeep Cherokee. |
| Indirect Cost Savings | | Significant savings relative to labor, inventory management, material handling, line space, rework |
| Direct Consumer Benefit | | This IP had zero buzz, squeak, rattle (BSR) at launch. Noise, vibration, harshness (NVH) is lower than customer requirements. First surface components are attached directly to IP retainer, reducing tolerance stack up and improving fit and finish. Overall result is a highly crafted, high performing integrated system. |
| Translates to other Vehicles? | | Can be translated to other vehicles. |
| Safety Benefits | | The Structural Instrument Panel manages energy loads and meets FMVSS 201 and 208 requirements with a minimum of steel reinforcements. Because it is vibration welded to other components, the aesthetic first surface also contributes to energy management performance. |
| Environmental Benefits | | Structural IP is made from the same resin. Also fewer attachments is conducive to disassembly |
| Additional Info | | The structural IP/Cockpit Module contributed significantly to the successful launch of an important vehicle. Program evolved to a Structual IP /Cockpit after cost, mass, and volume requirements were defined by the customer. This innovation was the result of close working customers relationship from the design studio through body-in-white and manufacturing, as well as key suppliers like Dow Automotive and Intertec Systems. |