Upload
parker-cockerell
View
217
Download
0
Tags:
Embed Size (px)
Citation preview
Industry-First, Mold-In-Color, High-Gloss, High-Touch Black Resin for Automotive Interiors
Robert D. Bedard
Product Development Engineer
Ford Motor Company
May 21, 2014
Panel 4: Innovative Materials
1
2
3
4
5
• PROJECT VISION
• TECHNOLOGY COMPARISON
• INNOVATIONS
• BENEFITS
• QUESTIONS & ANSWERS
Today’s Agenda
Hyundai Sonata
Fusion/Mondeo A8/A4 1 Series/F20
Corvette XJ/X351
High-Gloss Black interior finishes are popular in today’s vehicle themes
Industry Trend
– PROJECT VISION –
UTILIZE MOLD-IN-COLOR (PAINT-FREE)
TECHNOLOGY TO ACHIEVE JEWELRY-LIKE, HIGH-GLOSS, SOLID-COLOR AUTOMOTIVE
INTERIOR TRIM PANELS
Smart: Pleasing to the eye, and accentuates the interior theme & style. High-series appearance at affordable cost.
Quality: Tough enough to withstand the rigors of repetitive contact, use, and the external elements
Green: Manufactured without high-gloss paint, which is typically employed to make interior parts shine and to provide surface protection
This vision is aligned with Ford’s Primary Brand Pillars
– TECHNOLOGY COMPARISON –
CONVENTIONAL
VS.
NEXT-GENERATION
• The conventional injection molding process leaves surface defects on the visible surface of the component, such as weld-lines and flow-marks
• Paint must be used to:1) cover these surface defects 2) Achieve jet-black color, high-gloss, and deep, depth-of-image
Weld-lineFlow-mark
Conventional Technology
Resin Compounding Injection Molding Freight
Warehousing at Paint Supplier
Clean-Room Paint FacilityFreight
Sub-assembly
OEM
Conventional Value Chain for High-Gloss Paint
Long supplier chain, inefficient logistics, and scrap rate at paint shop all contribute to low, overall yield
– INNOVATIONS –
TOOLING DESIGN
MATERIAL SCIENCE
• A thermoplastic, in the liquid state, is injected into a mold. The thermoplastic then changes from a liquid state to a solid state, due to heat transfer into the mold’s walls.
• When a liquid thermoplastic is divided within the mold, the temperature at the front of the flow-front is higher than at the back of the flow-front. When two “cold” flow-fronts meet, a weld-line is produced.
• Solution: Control heat transfer by raising mold temperature as needed to reduce heat loss
Technology Breakthrough: Theory
a*
b*
*Advanced course on Applied Energy Engineering,Tokyo Tech OCW
Knit Line visible to naked eye Knit Line invisible to naked eye
• Electrically controlled heating elements are placed within the mold cavity to elevate the mold’s surface temperature above that which is used in conventional injection molding
• The cavity shell “floats” to enable efficient “heat-up” and “cool-down” phases of the molding cycle.
• The cavity shell is made of a special grade of stainless steel that provides both high thermal conductivity and high flexibility
Tooling Design Innovation1
2
3
1
2
3
• The heating elements within the cavity reduce flow-front heat loss, allowing the thermoplastic to flow and knit homogeneously within the injection mold. The elements are organized into zones, which govern heat delivery to respective regions within the cavity. A controller unit is used to tailor the amount of heat delivered to each zone, based on the amount of heat required to achieve exceptional surface finish for complicated component geometry.
Tooling Design Innovation
Conventional Cooling Method New Cooling Method
Tooling Design Innovation
• Water flows through a “circuit” to stabilize the temperature of the mold’s core
• Heat is rapidly extracted from the mold’s core through contact with a specially designed “cooling plate”
B
B
A
A
• Ford Motor Company and BASF Corporation partnered to develop an all-new polyamide resin used to manufacture the Fusion’s four door trim panel switch bezels; this was the automotive industry’s first application of paint-free, jewelry-like, jet-black trim panels located within interior high-touch zones
• This paint-free material science innovation was achieved via the following enablers: the use of exotic additives, optimization of the polymer formulation, and the use of specialized colorant packages
• Approximately 75 different iterations of additives, polymers, and colorants were extensively tested to hone in on the final formulation, in order to deliver depth-of-color and to meet durability requirements
BEFORE
AFTER
Material Science Innovation
BENEFITS
Pre-2011:
Jewelry-like
Painted
Finishes
Post-2011:
Jewelry-like
Mold-In-Color
Finishes
Component Design
Material Science
Tooling
TechnologyMolding
Technology
Long Supplier ChainCreation of VOCs & CO2
High Scrap RateHigh Hidden Factory costs
Shortened Supplier ChainMitigation of VOCs & CO2
Low Scrap RateReduced Hidden Factory costs
Technology enables a Paradigm Shift across the entire Value Chain
Ford Fusion Door Switch BezelsHigh-Touch, High-Gloss Black Mold-In-Color
36% COST
AVOIDANCE!
Mold-In-Color
Smart
Conventional Molding +Pigmented Base Coat &
Clear Top Coat
FutureOpportunity:
Forecasted Global Annual Volume: approximately
6 million units
FutureOpportunity:
Millions of dollars of revenue generated annually, per
additional Ford components
Approximately 40% savingsper Fusion, Mondeo door bezel
Several million dollars of incremental revenue generated per Fusion,
Mondeo
“The Tip of the Iceberg”More opportunities exist
across entire vehicles
Smart
• Mitigated paint-introduced quality defects like loss of adhesion, orange peel, dirt-in-paint, dry spray, etc.
• Strengthened product appeal in marketplace. For example, J.D. Power & Associates APEAL Study stated:
Quality
www.123rf.com
• Mitigated Volatile Organic Compounds (VOCs) and Carbon Dioxide (CO2) created by paint process
• Reduced CO2 emissions due to stream-lined Value Chain. An estimated 60,000 pounds of CO2 are mitigated annually from Ford Fusion production.
• Eliminated paint waste from entering landfills
• Improved health & safety via mitigation of exposure to harmful paint chemicals
Green
Ford Mondeo
Ford Edge
Ford Figo
High-Gloss Mold-In-ColorApplications in Development
• 2014 Automotive News PACE™ Innovation Partnership Award
• 2014 Automotive News PACE™ Innovation Award for Material Development
Recognitions
Materials Category Finalist with
BASF Corporation,
2012
Recognitions
On-line Publication,
2013
US Patent Office, 2013 & 2014
On-line Publication,
2013
Ford Motor Company: Engineering, Design, Development, &
Testing
H. M. Sun, M. Masserant, C. Boese, R. Bedard, D. Woods, C. Nielsen
BASF Corporation & Americhem, Incorporated : Resin & Colorant
Development
J. Leptich, H. Cowell, S. Tupper, S. Windahl, S. Hanley, T. Patel, B. Myers
Michael Tool & Mold, Synventive Molding Solutions, CUMSA: Tooling
M. Graf, J. Sulaiman, A. Hui, R. Cilia, R. Long, S. Navarra, J. de Fortuny
NADA Innovation: E-Mold Technology
M. Kang, D. Lee, K. Shin
Summit Polymers, Incorporated: Manufacturing
P. Bassett, K. Klimach, S. Crandall, K. Bulifant, M. Lazor, T. Loc
Our Team
QUESTIONS
&
ANSWERS
THANK YOU!
BACK-UP SLIDES
Home Appliances
Large Screen TVs
Technology migrated from consumer electronics to automotive. Ford leads in the automotive industry.
Automotive Interiors
Technology Evolution
2012 Ford Escape – High Gloss
2013 Ford Escape – Low Gloss
Technology Benchmarking: High-Gloss Black Finish Panels
SUPPLIER NAME OEM VEHICLE TECHNOLOGY PROCESSMITCHELL PLASTICS Chrysler, Ford, Toyota Jeep Liberty
Dodge DartDodge RamFord F150Toyota Corolla
In-Mold FilmBase coat / Clear coat paintUltraThermUltraCycle
In-Mold Film - Injection moldingPaint - Injection moldingUltraTherm / UltraCycle (proprietary)
ROCTOOL Volkswagen, Renault BMW F20, BMW F30, Audi A8, Peugeot 208
Mold-in-Color 3ITech rapid induction heating, rapid water cooling
KEY PLASTICS - EUROPE Ford, Volkswagen, General Motors, Tata
Ford - MondeoVW - Golf / PrototypeRenault - MeganeJaguar - XJ Schaltabdeckung, XJ, XKCitroen - B7 MikoAudi A8
Base Coat w/UV - VW, Ford, Audi, Skoda, Jaguar, PSAFilm - Jaguar, Citroen2 shot over molded - Jaguar, HighclassMold-in-Color - BMW, Audi, Jaguar
In-Mold Film / In-Mold DecorationHot Steam heating, Infrared Heater, Laser heating, Induction / Emold, Rapid Heating Ceramics (RHC)
FLEX N GATE General Motors, Ford, Chrysler, Toyota, Volkswagen, Nissan, Honda
Escalade, Cobalt, Impala, Suburban, Tahoe, Volt, Enclave, Town & Country, Caravan, Arcadia, Yukon, H3, Sentra, Cruze, Dakota, Ram, Colorado, Express, Savana
Base Coat - Base Coat + Top Coat -Film -
NADA Ford - Started Mass Production 2010General Motors - Started Mass Production 2012
Ford - C520, CD391, CD4.2GM - Corvette
Mold-in-Color Emold rapid heating / cooling
ASAHI KASEI Mazda, Toyota Mazda Axela (Mazda3) Mold-in-Color Stylac resinSABIC Chrysler Dodge Dart Mold-In-Color CYCOLOY™ and GELOY™
resins
BASF Chrysler, Ford, General Motors, Hyundai
CD391 Ultramid resin®