| Summary: |
The first application of High Performance Integration (HPI)
technology in North America, producing a highly crafted single piece
instrument panel with both a soft foam-in-place upper and a hard molded in
color lower. Cost savings
from lower tooling, manufacturing and assembly costs, material usage and
trimming operations of $15 per vehicle. |
| Most Innovative Feature: |
The technology produces a highly crafted, single piece IP
with both a soft foam-in-place upper and a hard molded-in-color lower.
IP components are also integrated. |
| Other Innovative Features: |
The Hostacom resin used for the IP retainer has excellent
mold-in-color and scratch resistant characteristics, thereby eliminating
the need for paint on the IP lower. |
| What Forming Process? |
IP skin - PVC slush molding; IP retainer - injection
molding; and foam-in-place (FIP) processing.
Standard processing equipment is used. |
| First Time Process Used: |
This is the first application of HPI technology in North
America. |
| Previous Process: |
Conventional IP's require attachments for components like
the defroster grille, center trim and end-of-panel (versus integrating these
parts). Significant
post-molding trimming operations (versus yielding a finished part right
out of the mold) are also eliminated. |
| Tooling Innovations: |
A patented mechanism in the skin/foam tooling allows the
accurate registration of the IP skin directly to the IP substrate -
creating a foam "shut-off."
This enables the precise placement of soft area on the IP surface
and "net no gap" aesthetics. |
| New Material Developments: |
High surface tension development of CB271PC for adhesion to
paint and foam while maintaining the highest balance of physical
properties and scratch resistance. |
| Weight Savings: |
(Coming from ITS). |
| Cost Savings: |
Reductions in tooling costs, manufacturing and assembly
costs, material usage and trimming operations total $15.00 per vehicle. |
| Cost Avoidance: |
N/A. |
| Direct Consumer Benefit: |
Multi-piece instrument panels can be a source of buzz,
squeak and rattle (BSR). By
reducing the number of components, component interfaces and mechanical attachments,
HPI significantly reduces potential BSR issues.
Unique styling and improved craftsmanship also enhances the
consumer's perceived value of the interior. |
| Translates to Other Vehicles?: |
Can be applied to any vehicle when a partial soft
instrument panel is appropriate for the segment. |
| Safety Benefits: |
None. |
| Environmental Benefits: |
Reduced material (no skin/foam runoff required) and reduced
paint use. |
| Additional Comments: |
HPI technology produces IP's with softness in the
"touch zones" and hardness in the non-touch zones.
This feature, combined with the uniform flushness and precision of
the integrated trim components, provides opportunities for enhanced
styling, craftsmanship and luxury. Unlike
other soft/hard solutions off one retainer, HPI uses foam in-place process
(versus foam-backed laminate) for a higher perceived luxury value. |
