| Description |
|
Upper Interior Hard Trim |
| OEM, Model, Model Year |
|
DaimlerChrysler, Dodge Ram, 2002 |
| System Supplier, Contact, Phone |
|
Johnson Controls, Inc., Fred Castator, (248)371-1080 |
| Molder/Processor, Contact and Phone |
|
Collins and Aikman, Steve Daugherty, (810)795-7947 |
| Toolmaker, Contact and Phone |
|
Collins and Aikman, Steve Daugherty, (810)795-7947 |
| Material Supplier, Contact and Phone |
|
ExxonMobil, John Lehning, (248)350-6510 |
| Generic resin type |
|
PP |
| Resin Trade Name |
|
Exxpol Enhance |
| Grade |
|
PP8114 |
| OEM Engineer, Title and Phone |
|
Jay Zocher, Head Impact Safety Enginner, (313)659-6179 |
| Nominated by, Company |
|
Jay Zocher, DaimlerChrysler Corporation |
| Address |
|
14250 Plymouth Road, Detroit, MI 48227 |
| Phone |
|
(313)659-6179 |
| Fax |
|
(313)653-5307 |
| Email |
|
jmz5@dcx.com |
| Summary | | One common material for upper interior hard trim meets all safety, ergonomic and aesthetic requirements. A-Pillar: Gas-assist molded in grab handle, attached covers for screw bosses. Unique rib cartridges used to meet head impact requirements. Weight Savings: Gas-assist handle saves weight over vinyl molded over steel handles.. Cost Savings: N/A Cost Avoidance: Reduced parts, simplified assembly. |
| Most Innovative Feature | | One common plastic material for upper interior hard trim meets all safety, ergonomic and aesthetic requirements. |
| Other Innovative Features | | A-Pillar: Gas-assist molded in grab handle, attached covers for screw bosses. Quad B-Pillar: Rib Cartridge molded with living hinge to get slits in the ribs in the direction needed for safety and allow it to be bent for installation into B-Pillar, rib cartridge also retains ATL slider, and it is sonic welded to the trim to eliminate glue, seperate gas-assist grab handle comes PIA to the part and includes attached covers for screw bosses. |
| Forming Process | | Injection Molding and Gas-Assist Injection Molding. |
| First time process used? | | Molded in gas-assist grab handle on the A-Pillar is first in industry. |
| Previous Process Used | | Previously used glue to attach rib cartridges to the hard trim, used separate vinyl molded over steel grab handles and separate covers for screw bosses, used brushes instead of a slider to cover up ATL slot. |
| Tooling Innovations | | Molded in gas-assist grab handle on the A-Pillar required A-Surface action to create handle. Other trim parts required lifters to create wrap flanges. Quad B-Pillar rib cartridge required molding the parts folded open with a living hinge to get slits on both sides of it in the line of draw. |
| New Material Developments | | None - existing material |
| Weight Savings | | Gas-assist handle saves weight over vinyl molded over steel handles, PP8114 is one of the lower density plastics designed to meet FMVSS 201. |
| Direct Cost Savings | | Sonic welding eliminates cost of glue, molded in handle eliminates separate handle, gas-assist handle is cheaper than vinyl molded over steel, PP8114 is one of the lower cost plastics designed to meet FMVSS 201. |
| Indirect Cost Savings | | All necessary parts (rib cartridges, grab handles, covers for screw bosses, ATL sliders) come in PIA to avoid additional labor at assembly plants. Parts install to vehicle with PIA clips, and only require screws be driven for the grab handles. |
| Direct Consumer Benefit | | Improves Head Impact Safety, provides ingress/egress grab handles at all four doors, maximizes driver visibilty, provides aesthetic appeal by meeting color, grain, gloss, fit and finish requirements. |
| Translates to other Vehicles? | | Actual hard trim is unique to Dodge Ram, but concepts can be easily translated to other vehicle lines. |
| Safety Benefits | | Complies with new Head Impact Safety Standard FMVSS201, withstands Side Airbag Curtain deployment at temperature extremes. |
| Environmental Benefits | | One common material for all parts, and sonic-weld attachment of the rib cartridges (instead of glue), allows ease of recyclability. |
| Additional Info | | ATL Slider and Quad C-Pillar Rib Cartridge have molded in features to help direct Side Airbag deployment. |