| Summary: |
Metal to plastics conversion of clutch pedal support.
Weight savings: 1 lb (57%). Cost
savings: $5 per assembly. |
| Most Innovative Feature: |
Weight Saving from Metal 800 grams to Plastics 346 grams
(Total Saving = 1 lbs.) |
| Other Innovative Features: |
Estimated Cost Saving of € 5,- Euro per assembly due to
design advantages in long glass fiber plastics. |
| What Forming Process? |
Injection Molding. |
| First Time Process Used: |
Yes. |
| Previous Process: |
Replaced Metal Part Assembly, which was cut, bend, welded,
etc. |
| Tooling Innovations: |
No extra tooling innovations needed to produce LGF-Material.
That's an advantage! |
| New Material Developments: |
Patented Pultrusion process of long-glass fiber plastics
material by GE Plastics- LNP, named
VERTON Technology. |
| Weight Savings: |
From 800 grams (1.76 lbs) to 346 grams (0.76 lbs) = 454
grams (1 lbs.) Weight Savings. |
| Cost Savings: |
€ 5 Euro/Assembly (equals to 5 USD/Assembly) |
| Cost Avoidance: |
Reduced Assembly time. Integrated Bayonet Lock (plug and
turn) of master cylinder. This way you spare 4 bolts and nuts and the
assembly time for that. |
| Direct Consumer Benefit: |
No direct benefit. |
| Translates to Other Vehicles?: |
Highly translatable to all manual gear shift cars. Modular
use for several car platforms. For Automatic transmission you can easily
leave this part out. |
| Safety Benefits: |
Master Cylinder is hidden/protected inside Clutch Support.
Support is symmetrically loaded by master cylinder. |
| Environmental Benefits: |
Ease of disassembly and recyclable materials used. |
| Additional Comments: |
Long glass fiber VERTON MFX 700-10 HS is capable of
withstanding load testing of:
- 450 Newton side load at
pedal – no break
- 1500 Newton “in plane”
load at pedal – no break |
