| Summary: |
Using the MuCell process, production of sound enclosure
systems with reduced molded-in stress improving flatness by 55%. Cost
savings: 15% from reduced cycle times (10-15%), reduction in molding machine
size and part weight (4%). |
| Most Innovative Feature: |
The MuCell process substantially reduced molded-in stress
improving flatness. This resulted in significant weld process yield and
cycle throughput. |
| Other Innovative Features: |
Process benefits include, 10-15%cycle time reduction, 33%
reduction in the injection molding machine size, 4% part weight savings.
Flatness improvement of 55%. |
| What Forming Process? |
The MuCell injection molding process. |
| First Time Process Used: |
Yes, development of MuCell technology for this application
in sound enclosure systems represents a significant opportunity to reduce
manufacturing costs and improve part quality. |
| Previous Process: |
Conventional injection molding. |
| Tooling Innovations: |
None; Direct sprue gate diameter reduced 25% vs. typical.
Attention to heat exchange details, such as amount and placement of cooling
lines, thermal pins for mounting boss cores, and core-outs to achieve wall
uniformity in all part details helped optimize the cycle and direct material
reduction opportunities. |
| New Material Developments: |
Standard PP with optimized melt temperature to achieve
desired surface finish. |
| Weight Savings: |
Top Half - 8%; Bottom Half - 4% |
| Cost Savings: |
Plastic part cost savings of 15% were realized using the
MuCell process. |
| Cost Avoidance: |
Cavity pressure reductions >50% support future tool
maintenance cost savings and extended tool life for these high surface area
- high molding tonnage applications. |
| Direct Consumer Benefit: |
Less material usage resulting in reduced vehicle weight -
improved fuel efficiency. |
| Translates to Other Vehicles?: |
Yes, Injection molded sound enclosure of all types can be
manufactured utilizing the MuCell process. |
| Safety Benefits: |
None. |
| Environmental Benefits: |
The SCF and gas used to facilitate the process are
non-toxic nitrogen based rather than gas derived from the thermal breakdown
of chemical based blowing agents. |
| Additional Comments: |
Harman Becker is a leading innovator in Automotive sound
systems under the JBL and Infinity logos. The use of new "innovative"
technologies has led to many of the sound developments Harman has adopted.
We see the MuCell process technology as another innovative technology that
can bring value and product improvement to our OEM customers. |
