| Summary: |
Interior part that combines two TPO components (foam and
carpet) to form a light weight, resilient, self supporting cargo area
protection system. Weight savings: 85%. Cost savings: 15%. |
| Most Innovative Feature: |
This interior part combines two TPO components (foam and
carpet) to form a light weight, resilient, self supporting cargo area
protection system. |
| Other Innovative Features: |
The two different types of TPO products (foam and carpet)
are physically combined and not easily separated, yet are repelletized
together and used again in the foam extrusion process. |
| What Forming Process? |
Foam extrusion, flame laminating, compression molding. |
| First Time Process Used: |
Yes! |
| Previous Process: |
Vacuum formed ABS or HDPE, Injection molding, Die cut and
scored hard board. |
| Tooling Innovations: |
Large tool design (5' x 11') that allowed the entire
interior system to be molded in one blank. |
| New Material Developments: |
Special additives were compounded with the base resin to
allow part flexibility and resilience. |
| Weight Savings: |
85% |
| Cost Savings: |
15% |
| Cost Avoidance: |
10% |
| Direct Consumer Benefit: |
Yes, this interior design maximizes the cubic volume of the
cargo area, while reducing the vehicle weight, increasing fuel economy,
provides thermal and sound insulation. This padded interior design not only
protects the vehicle, but also it's contents. |
| Translates to Other Vehicles?: |
Absolutely! |
| Safety Benefits: |
Meets all Federal Motor Vehicle Safety Standards. |
| Environmental Benefits: |
The all TPO construction allows the trimmed off-fall to be
repelletized and reused back in the foam extrusion process. There are no
materials that need to be hauled to a landfill for this entire manufacturing
process. |
| Additional Comments: |
The final customer, the U.S. Postal Service, will reap the
benefits of this part design by decreasing it's cost and improving employee
morale. |
