Innovation was in the air at each gala for two major automotive plastics award competitions in 2015, one on each side of the Atlantic. Here’s an overview of the winners.

SPE Automotive Innovation Awards

For November’s 45^th-annual SPE Automotive Innovation Awards, category winners and the Grand Award winner were selected from finalists by a “Blue Ribbon” judging panel composed of journalists, academics, and retired industry chief engineers. This SPE Automotive Division awards competition is the oldest and largest of its kind in the world, drawing submissions from dozens of teams made up of OEMs, tier suppliers, and polymer producers—all seeking the title of “The Year’s Most Innovative Use Of Plastics.”

The annual event typically draws over 700 OEM engineers, automotive and plastics industry executives, and media. Fund raised from the event are used to support SPE educational efforts and technical seminars, which help educate and secure the role of plastics in the advancement of the automobile.

Grand Award

The Grand Award winner (and Materials Category winner) was the ultralight Class A body panels for the General Motors Chevrolet Corvette. The material (TCA Ultra Lite SMC) is a 1.2-specific gravity (SG) compression-molded sheet molding compound. It eliminated 9 kg of body-panel weight after “a running change” from the previous mid-density grade of the material, requiring no tooling changes.

Suitable for Class A or structural components, the new composite offers a 28% mass reduction compared to mid-density (1.6 SG) SMC grades, and 43% versus conventional (1.9 SG) SMC. It reportedly provides other benefits when compared to metal, including reduced weight and tooling costs, enhanced design flexibility, corrosion and dent resistance, and superior surface finish. Key to achieving the ultralow density was the replacement of calcium carbonate filler with hollow-glass microspheres, plus the use of a proprietary surface treatment to significantly improve the resin/reinforcement interface.

The tier supplier and processor was Continental Structural Plastics, and the material supplier and toolmaking team was Continental Structural Plastics, Century Tool & Gage, and Paragon Die & Engineering Co.

Category winners

The event’s category winners are summarized as follows:

Category: Body Exterior

• Winner: Push-to-release exterior serviceability fastener
• OEM Make & Model: 2015 Ford Motor Co. Mustang sports car
• Tier Supplier/Processor: ITW Deltar Fasteners
• Material Supplier / Toolmaker: Ascend Performance Materials, LLC / A&P Tool, Inc. and M&M Tool and Mold, LLC
• Material / Process: PA 6/6 / injection molding
• Description: Compared to other easy-service fasteners, which have twist heads to release, this injection-molded PA 6/6 fastener only requires that you push the center pin to the service position to remove. This fastener cannot back out or be removed from the installed position without deliberate actions by the customer. The fastener is reusable, unlike other push pins, and reduces the time needed to remove the fastener by 90%, without tools.

Category: Body Interior

• Winner: Rear-seat folding head restraint
• OEM Make & Model: 2015 Ford Motor Co. F-150 pickup
• Tier Supplier/Processor: Windsor Machine Group / Hawk Plastics Ltd.
• Material Supplier / Toolmaker: ExxonMobil Chemical Co. / IRC Engineering
• Material / Process: PP copolymer / injection molding
• Description: This rear-seat folding head restraint eliminates a welded steel structure and replaces it with a single-piece, living-hinge plastic core as its main structural component. As a result, thickness is reduced 33 mm for improved comfort and rear visibility; mass is reduced by 624 g per vehicle; manufacturing complexity is significantly reduced; tooling costs are lowered; and piece price is reduced by $1.50 per vehicle.

Category: Chassis/Hardware

• Winner: Fiberglass/epoxy composite coil spring
• OEM Make & Model: 2015 Audi AG A6 Avant wagon
• Tier Supplier/Processor: S. Ara Composite S.A.S.
• Material Supplier: Hexion Inc.
• Material / Process: Epikote epoxy + fiberglass / modified filament winding
• Description: This weight-saving epoxy/fiberglass composite coil spring is reportedly the first of its kind to be used in the suspension system of a series-production vehicle. Using a patented, modified filament-winding process, the application replaced traditional steel coil springs, reducing weight 40% and enabling the suspension system to react more quickly to changing road surface conditions.

Category: Environmental

• Winner: Seat fabric from recycled materials
• OEM Make & Model: 2015 Ford Motor Co. F-150 pickup
• Tier Supplier/Processor: Johnson Controls Inc. / Sage Automotive Interiors
• Material Supplier: Unifi Manufacturing, Inc.
• Material / Process: Repreve PET / multiple
• Description: The fiber used in this innovative seat fabric is made from a hybrid blend of 100% recycled materials, including post-industrial fiber and post-consumer water bottles. The fabric meets Ford design and comfort requirements without any compromise in quality, durability, or performance. The switch from virgin fiber was achieved at cost parity, while diverting over 5-million water bottles from landfills just this year.

Category: Powertrain

• Winner: Heated-tip fuel injector
• OEM Make & Model: 2015 Honda Motor Co. Fit subcompact and City sedan
• Tier Supplier/Processor: Delphi Powertrain
• Material Supplier / Toolmaker: DuPont Automotive / Coltelleria Baldi
• Material / Process: Zytel HTN54G35EF BKB336 PPA / injection molding
• Description: An electrical heater within the injector is energized by the vehicle controller, rapidly heating the ethanol fuel and dramatically improving vaporization while reducing emissions. Keys to success were the ink materials used in construction of the heater, body design, the ink-printing process on the body, and overmolding with PPA. The technology saved $60 and 8.8 kg per vehicle.

Category: Process/Assembly/Enabling Technologies

• Winner: “IMX” instrument panel (IP)
• OEM Make & Model: 2014 Hyundai Motor Group i20 supermini
• Tier Supplier/Processor: Hyundai-Mobis / HanilEhwa
• Material Supplier / Toolmaker: Hanwha L&C / Hyundai-Motor Co.
• Material / Process: Multiflex 3202 TPO / compression-injection molding
• Description: To eliminate scratches and a hard “plastic” feel, a two-shot compression-injection soft IP was developed. The back-foamed TPO foil is compression-injected with the PP substrate, which in turn is integrally injection molded with the TPO passenger-side airbag door, all in a single tool (“IMX”). The resulting part saves $10 per vehicle and reduces mass by 300 g.
  
  

Category: Safety

• Winner: Floor rocker reinforcement
• OEM Make & Model: 2015 FCA US LLC Jeep Renegade SUV
• Tier Supplier/Processor: Proma Group / Redstamp
• Material Supplier / Toolmaker: SABIC / Redstamp
• Material / Process: Noryl GTX 910 MPPE/PA / injection molding
• Description: An optimized MPPE/PA 6 honeycomb geometry in a plastic/metal hybrid proved to be a very efficient energy-absorbing crash-box structure in this floor rocker reinforcement. Not only is the component E-coat capable, but it’s very easy to assemble into the vehicle’s body-in-white (BIW). Since the plastic honeycomb is integrally attached to two steel flanges during injection molding, no structural adhesives are needed, and the mixed-material solution took 1 kg of weight out of the BIW.

Category: Aftermarket

• Winner: Transparent lightweight wind deflector
• OEM Make & Model: 2016 General Motors Co. Corvette Stingray convertible sports car
• Tier Supplier/Processor: Polytec FOHA Inc. / SABIC
• Material Supplier / Toolmaker: SABIC / Pace Machine Tool, Inc.
• Material / Process: Lexan 9043 PC with Exatec 900 coating / CNC-trimmed sheet
• Description: This is the first use of a self-mounted, transparent, and frameless wind deflector for convertible cars that meets AS2 ANSI and ECE requirements. The steeply raked design minimizes air turbulence and noise when the top is down. Replacing glass with PC lowered mass 33% and allowed a contoured shape to be achieved.

SPE Central Europe Automotive Awards

In the other major automotive plastics awards of 2015, the competition went down to the wire: Neither the jurors nor the participants in the SPE Central Europe Automotive Awards had any idea before awards night which components or media would receive the coveted awards. Even the most experienced jury members were surprised by the ideas and technical solutions being presented that night. As Rudolf Fernengel, coordinator of the Awards’ “parts & components” categories, said, “A short while ago I would have thought some of the developments shown here [could] not be realized.”

Since 1992 the Internationale Gesellschaft für Kunststofftechnik (SPE Central Europe) has announced its Automotive Division Awards every 18 months. “The [Awards enjoy] a high priority because of the high quality of the submissions and the objective assessment criteria,” said Klaus-Dieter Johnke, president of the SPE Central Europe Section, in his summary of the event. The competition was and is supported by many companies; in 2015 year the awards were sponsored by A. Schulman, Akro-Plastic, Albis Plastic, Celanese, Demat (EuroMold), DSM Engineering Plastics, EMS-Chemie, Frimo Group, Grafe Advanced Polymers, and KraussMaffei Technologies.

Sustainable solutions, skillfully communicated

Not found in nature are the animals of the ad series “Two Worlds” by Grafe Advanced Polymers, which won the award in the category “image / product ad.” In second place was the ad campaign for the 50th corporate anniversary of Frimo, and third place went to the display “In Touch with Plastics” by Albis Plastic and to the advertisement “We have made the smallest to the top of the class. The new CX.” by KraussMaffei Technologies.

The award in the category “image / annual report” was accepted with pleasure by Wolfgang Leonhardt for the short, informative “Image Report 2014.” “The slogan on the front page—creative, innovative, precise—fits well with the company,” said the jury.

From the submissions in the category “digital medium,” the video “Erodable high performance ceramics for mold inserts” from Leroxid emerged as the winner. It shows how ceramic inserts protect molds against wear from abrasive materials. In second place was the “Plastics Joining Configurator” app of Frimo Group. And third place went to the presentation film “Be Color! Color your difference,” from A. Schulman.

In the category “image/product brochure” there were two top awards. One was received by Albis Plastic for its brochures titled “Your Advantage.” In one company brochure and four sector brochures, the company showed off its expertise for industry-specific solutions. The second award went to Volkswagen for a new book which will be presented to visitors in memory of their tours at its factory. The second-place award went to the product brochure “Leiden schafft Leichtbau” by Akro-Plastic, and third place went to the brochure “Be Color! Color your difference,” by A. Schulman.

Long-term-oriented strategic thinking is reflected by Grafe Advanced Polymers’ color trends for each coming year. For 2016, the Thuringian artist Max Kosta created graffiti that was photographed and combined into a calendar called “Urban Inspiration – Color Preview 2016.” The calendar’s concept, design, color descriptions, typography, and graphic design were well thought-out and coordinated, and the jury awarded it a Grand Innovation Award.

Highly innovative, and future oriented

A thermoplastic bearing structure for instrument panels from BMW Landshut won the “body interior” category. It’s said to be the world’s first such structure in pure thermoplastic, and reduces component weight compared to both steel and magnesium. Second place was won by a center console decoration strip from BIA Kunststoff-und Galvanotechnik. Third place was shared by a lightweight air duct by BMW and fan nozzles from Fischer Automotive Systems. And fourth place went to a lightweight glove box enclosure made in Landshut, while door trim from Magna Interiors Ebergassing ended up in fifth place.

The lead award in the “body exterior”category was won by a front cover made from the new material Litecor®, developed at Volkswagen. The steel-plastic-steel sandwich composite reportedly is KTL-compatible and can be processed in the same tool and the same manufacturing process as the conventional material. In second place was an air guide for a condenser with an intercooler from Kunststofftechnik Backhaus. Third place was taken by an Airpanel cooler fairing with adaptive closing function from Montaplast and Mirror Controls International. The lightweight roof module of F.S. Fehrer Automotive took fourth place in this category.

A pedal bearing block won the award in the “power train” category. It’s produced with the water injection technology (WIT) process in polyamide reinforced with 15% carbon fiber. The special features of the safety-related part are weight reduction and higher stiffness, and the fibers come from production waste. Second place went to a filling system of Röchling Automotive. The next three places were won by Mann + Hummel for, respectively, a suction tube with duct shutdown, an injection-molded bellows, and an active cooling thermal management valve. A pressure pin of a brake piston from Kunststofftechnik Backhaus also shared fifth place.

In the category “electronical / optical parts,” a touchpad from Continental Automotive won first place. In second place was a toggle button by BIA Kunststoff- und Galvanotechnik, and a mirror holder for head-up displays from Continental landed in third place.

Special awards

For outstanding innovations among the submitted automotive components, the jury gave “Innovation Awards.” In the category “body interior,” the jury favored the “self-healing bionic surfaces” of Rühl Puromer, whose detailed sharkskin textures are made with a special surface and tooling technology. The low processing viscosity of the company’s Puroclear® system, with coloring and “self-separating” properties—a novelty in polyurethane surface technology—reportedly makes the surfaces possible.

In the “body exterior” category, the jury was impressed by a bonnet and hard-top with a bionic surface, submitted by the Frimo Group. Through the use of modified tooling and machinery, it’s able to represent complex and functional surfaces in an economical off-tool production process. These components received anInnovation Award.

Meanwhile, even the most experienced jury member thought it was not possible to achieve the excellent surface roughness values of Rz < 4 in the cylinder walls of a gear actuator module made from long-fiber-reinforced polyphthalamide. This part, from FTE Automotive, is functional over a temperature range of -40 to +140°C, has low tendency to creep, and resists degradation from permanent contact with transmission fluid. The technology won a Grand Innovation Award.

The Awards’ top winner was a touchpad system developed by Continental Automotive. The touchpad, for controlling navigation, the audio system, hands-free calling, and other functions, has a scratch-resistant surface. Its production combines a film insert, injection molding, and in-mold scratch-resistant coating into one manufacturing process. This part had the highest combined score of the SPE Central Europe Automotive Awards in 2015, and thus won the Grand Award.

Note: This article was based on information and texts contributed by Peggy Malnati, SPE Automotive Div. Committee Chair, and Ursula Mellema, for the SPE Central Europe Section.