Polypropylene Foam Air Cap
2004 Ford V229 Freestar



Nominee Number: 34 Result: Nominee
Category: Materials Description: Polypropylene Foam Air Cap
OEM: Ford Model: V229 Freestar
Model Year: 2004 System Supplier: Intier Automotive
System Contact: Dan Asbury System Phone: 248-567-4744
Model/Processor: Oji Intertech Molder Contact: John Fredrick
Molder Phone: 248-373-7733 Toolmaker: Century Tool
Tool Contact: Ken Huber Tool Phone: -
Material Supplier: - Material Contact: -
Material Phone: - Generic Resin Type: -
Resin Trade Name: - Grade: -
OEM Engineer: John Mardeusz OEM Title: Design & Release Engineer
OEM Phone: 313-206-3265 Name of Nominee: Tom Bailey
Nominee's Company: Intier Automotive Nominee's Address: 39600 Lewis Drive
Novi, MI 48377
Nominee's Phone: 248-567-4590 Nominee's Fax: 248-567-4996
Nominee's Email: tom.bailey@intier.com    
Summary: Various polymers are combined to create an unique air passage that routes HVAC air to rear seat passengers without allowing the air to heat-up.  Weight savings: 10-15%.  Cost savings: 20%.
Most Innovative Feature: The combination of various polymers to create an unique air passage that routes HVAC air to rear seat passengers without allowing the air to heat-up.
Other Innovative Features: The use of polymer stiffening films in combination with metalized films and cross linked foam.
What Forming Process? Thermoformed in a compression.
First Time Process Used: Yes!
Previous Process: Blow molded ABS, Polyurethanes.
Tooling Innovations: N/A.
New Material Developments: Stiffening films for added strength and rigidity; metalized film to reflect heat.
Weight Savings: 10 to 15%.
Cost Savings: 20%.
Cost Avoidance: N/A.
Direct Consumer Benefit: More consistent temperature in rear passenger zones.
Translates to Other Vehicles?: Yes.
Safety Benefits: None.
Environmental Benefits: Completely recyclable.
Additional Comments: This product is currently Program direction for future OEM programs.