| Summary: |
The first all polyolefin construction, soft touch pull
handle manufactured using a three shot process which provides enhanced
performance. Weight savings: 30%. Cost savings: 25%. |
| Most Innovative Feature: |
First all polyolefin construction, soft touch pull handle
manufactured using three shot process, which provides enhanced performance
while setting a new market price point for competitiveness. |
| Other Innovative Features: |
Provides "dry" feel and low gloss aesthetics to meet OEM's
styling requirements using a PVC Free system. The system offers a rich look
outer layer. The second layer uses a recycled PP for cost benefit. The
inner layer provides the structural integrity using a glass filled PP. The
adhesion between the layers is achieved by chemical bonding as opposed to
traditional mechanical interlocks. The total polyolefinic system is
recyclable. |
| What Forming Process? |
Three shot injection molding. |
| First Time Process Used: |
Yes. |
| Previous Process: |
PVC over mold onto PP substrate using mechanical
interlocks; Utilizes higher cost and less robust hand transfer system and
use of multiple molds. |
| Tooling Innovations: |
Lift and turn technology that automatically moves entire
part into new core/cavity steel on each shot; Unique articulation of tool
and use of copper alloys/other special materials for rapid heat removal. |
| New Material Developments: |
The material formulation was tailored to achieve the OEM's
aesthetics and feel. In addition, the flow was tailored to accommodate the
process. |
| Weight Savings: |
30% weight savings due to specific gravity of Invision
versus PVC. |
| Cost Savings: |
Reduced part cost by 25%. |
| Cost Avoidance: |
The totally automated process, which utilizes robotic
removal, produces four parts (2 RH, 2LH) in ~60 seconds. Some previously
used processes typically produce 2 parts in ~ 90 seconds. |
| Direct Consumer Benefit: |
It offers the consumer the rich look and soft touch feel.
It reduces fogging and odor. The color and gloss stability is significantly
enhanced. Fit is enhanced by increased dimensional stability and less
part-to-part variation. |
| Translates to Other Vehicles?: |
Can be translated to other OEM's and vehicle lines. |
| Safety Benefits: |
None. |
| Environmental Benefits: |
All polyolefin based pull handle system that allows for
ease of recyclability. The inner layer utilizes 100% recycled PP. |
| Additional Comments: |
The unique application of simultaneous engineering and
teamwork produced a system that is considered a trend setter for pull handle
applications as it raises the standards of part performance while reducing
the total systems costs through material, design, and process innovations. |
