CSP to supply Ford with composite engine shroud

 

 

Continental Structural Plastics (CSP; Auburn Hills, Mich., U.S.) has announced that it is supplying Ford Motor Co. (Detroit, Mich., U.S.) with a composite, dual wall dash engine shroud for use in the 2020 Ford Explorer. This sheet molded compound (SMC) advanced composite shroud will reportedly reduce powertrain noise, vibration and harshness (NVH) experienced in the vehicle cabin.

Developed in collaboration with Ford using the tools in Ford’s new NVH lab, the composite engine shroud is said to create an air gap between the engine compartment and the steel front bulkhead by wrapping around the back of the engine and meeting the strut towers on each side of the engine bay.

According to CSP, benefits of the composite dual wall dash compared to steel or other materials include an improved sound barrier; a reduced mass, at just 12 pounds for the four-piece assembly; and the moldability and design flexibility to support a complex, under‐hood packaging environment. The composite dual-wall-dash is also said to:

• reduce engine noise,
• improve acoustics by dissipating sound before it reaches the primary dash panel,
• provide superior thermal protection for electrical components, and
• accommodate engine assembly and serviceability concerns.

“Composites are a great choice for a number of under‐the‐hood applications, because of these properties and the design flexibility they provide,” says Bryan Ludwig, business development director at CSP. “Because our glass fiber composite is a thermoset, it actually offers better thermal properties than a metal, and can be molded thin enough to fit in the tight spaces found in the engine compartment.”

 

 

“We are continually looking for ways to help our customers meet design and engineering challenges by using our composite materials,” says Steve Rooney, CEO of CSP. “Because of the superior dampening qualities offered by a composite, Ford was able to achieve a level of cabin quietness that will enhance the driving experience for Explorer and Aviator owners.”

The dual wall dash is being manufactured at the Continental Structural Plastics facility in Conneaut, Ohio. This 190,000 square‐foot facility sits on 33 acres in northeastern Ohio, and employs 260 people.