Published 11/4/2022

SPE Automotive Division names winners for 51st annual Innovation Awards competition

Ten category winners, the Vehicle Engineering Team Award and the reveal of the Lifetime Achievement Award winner were announced at the in-person event, acknowledging numerous composite innovations.

Automotive

Edited by: Grace Nehls

Senior Managing Editor, CompositesWorld

Grand Category Award and Category Winner: Chassis/Hardware

Tension Leaf Spring

OEM make and model: 2022 General Motors Co. Chevrolet Silverado and GMC Sierra
Tier supplier/processor: Mubea (Muhr und Bender KG)
Material supplier/toolmaker: Multiple/Mubea
Material/process: Epoxy/prepreg layup and compression molding

The all-composite leaf spring for light truck programs reduces mass up to 75% versus all-steel and 58% versus hybrid steel/composite solutions while doubling durability, eliminating corrosion, improving ride comfort, lowering noise, vibration and harshness (NVH) and increasing payload. Fiberglass-reinforced epoxy prepreg is used to form a single leaf with a progressive spring rate that eliminates the shackle, shackle bushing and helper leaves, yet passes all OEM test requirements.

Category Winner: Additive Manufacturing

Spoiler Closeout Seal

OEM make and model: 2022 General Motors Co. Chevrolet Tahoe, Chevrolet Suburban, Cadillac Escalade, GMC Yukon
Tier supplier/processor: HP Inc. and AMT Ltd./GKN Additive (Forecast 3D)
Material supplier/toolmaker: BASF Corp./GKN Additive
Material/process: BASF SE Ultrasint TPU01 thermoplastic polyurethane (TPU)/HP Multi Jet Fusion 5200 Series

The powder bed fusion (PBF) process was used to source, print, process and install 60,000 TPU spoiler closeout seals to meet 10 weeks of production as a bridge solution while hard tooling was being produced. Innovative vapor polishing and drying processes cleared a bottleneck, halved production time, were used to finish parts, eliminating the need for post-print dyeing. The seals close out gaps on left and right sides of rear spoiler, improving finish and fuel efficiency.

Category Winner: Aftermarket and limited edition/specialty vehicles

Carbon Fiber C-Brace

OEM make and model: 2022 Ford Motor Co. Ford Bronco Raptor
Tier supplier/processor: Montaplast of North America
Material supplier/toolmaker: BASF Corp./Commercial Tool Group
Material/process: Ultramid B3WC4 HP CF and GR PA6/injection molding

Carbon fiber C-brace. Photo Credit: Montaplast of North America, BASF Corp./Commercial Tool Group

This customer-visible, Class A C-brace was designed to meet offroad desert durability requirements for convertible versions of the vehicle while boosting torsional stiffness 40% to improve handling and NVH. Weight was reduced 55% versus aluminum and 85% versus steel by adopting a sandwich composite approach. Upper and lower shells were injection molded in 35% GR PA6 while a core was injection molded in 20% CF-PA6, then components were bonded with a newly formulated methacrylate adhesive.

Category Winner: Body Exterior

Panoramic Sunroof Frame

OEM make and model: 2022 Hyundai Motor Group Kia Sorento
Tier supplier: Inalfa Roof Systems Korea
Material supplier: GS Caltex Corp.
Material/process: Hiprene ALG14BF PA6/injection molding

Several novel technologies contributed to this large injection-molded LFT-PA6 panoramic sunroof frame. First, flat rather than round glass fibers provided higher dimensional stability and reduced warpage. Second, the twist pultrusion was used to produce long fiber-reinforced thermoplatic (LFT) pellets whose fiber length exceeds the length of the pellets, again contributing to mechanical improvements. Weight was reduced 51% and part count dropped from 33 to four versus a steel frame. Compared to carbon fiber-reinforced LFT, torsional rigidity was 13% higher and breaking force 25% optimized at 24% lower cost.

Category Winner: Body Interior

Second Row Seat Backs and Cushions

OEM make and model: 2022 Toyota Motor Corp. Toyota Tundra
Tier supplier/processor: Flex-N-Gate Corp. and Adient/Flex-N-Gate Corp. and L&L Products
Material supplier/toolmaker: BASF Corp./SyBridge Technologies
Material/process: Ultramid B3ZG7 35% GR-PA6 and Elastocoat 74850 80% GR-PUR PA6 and PU/pultrusion and injection overmolding

Photo Credit: Flex-N-Gate Corp., Adient, L&L Products, BASF Corp. and SyBridge Technologies

This composite seat structure combines a pultruded continuous fiberglass-reinforced polyurethane (PUR) reinforcement beam that is injection overmolded with short glass/PA6 to form the seat frame geometry. By replacing a 60-piece high-strength steel frame structure with a four-piece molded composite structure, significant crash performance improvements were achieved while both cost and mass targets of 20% reduction were met. Additionally, more than 100 welds at 16 weld stations were eliminated, improving quality control and under-seat storage that wasn’t possible with the previous solution was added.

Category Winner: Electric and Autonomous Vehicle Systems

High-Voltage Power Distribution System

OEM make and model: 2022 Ford F-150 Lightning
Tier supplier/processor: Aptiv PLC/Yazaki North America Inc.
Material supplier: DuPont de Nemours Inc.
Material/process: Crastin FR684 and HR5339 PBT/injection molding, silicone overmolding

This customizable, shielded high-voltage power distribution system permits seven sets of subassemblies and up to 64 possible configurations from a single tool, providing both flexibility and scalability for future programs. Three different materials are used: A flame retardant 25% GR-PBT forms the internal assembly and terminal blocks and a silicone seal is overmolded directly onto a 30% GR-PBT cover. A unique shielding system uses stamped connection interfaces that reduce mass by two-thirds versus cast products while maintaining electromagnetic shielding.

Category Winner: Materials

Thermoplastic BEV Thermal Management Solution

OEM make and model: 2023 General Motors Co. Cadillac Lyriq
Tier supplier/processor: Cooper Standard Automotive Inc.
Material supplier/toolmaker: DuPont de Nemours Inc., Dow Chemical Co., LyondellBasell Industries/Cooper Standard Automotive Inc.
Material/process: PA6/12, PA66 and PP/extrusion, molding, forming and automated assembly

Two developments provide a lightweight, thermoplastic solution for electric vehicle (EV) thermal management systems. PlastiCool 2000 multilayer tubing for glycol applications to 120°C provides excellent chemical resistance, 25% better permeation resistance and 60% lower weight than EPDM, and is available in smooth, convoluted, round and non-round configurations. Ergo-Lock+ modular VDA connectors are flexible, offer visual and scannable latch verification, and reduce insertion forces >30%. The system’s modularity permits hundreds of connector configurations to be produced from a standard set of molded subcomponents at lower total cost.

Category Winner: Powertrain

High-Pressure Oil Cooler Gasket Seal

OEM make and model: 2022 General Motors Co. Chevrolet Silverado and GMC Sierra
Tier supplier/processor: Uchiyama Marketing & Development America LLC
Material supplier/toolmaker: Uchiyama Marketing & Development America LLC and DuPont de Nemours Inc./Uchiyama Marketing & Development America LLC
Material/process: UMC V7401 Ethylene Acrylic Elastomeric Plastic/injection molding

Oil cooler gaskets are small parts with important sealing functions between oil coolers and oil pumps in demanding engine environments. To eliminate leaks seen with fluorocarbon seals during temperature cycling, a new ethylene acrylic TPV was developed. It offers low-temperature sealing and maintains good compression set and controlled oil swelling from -40° to 150°C and 14 bars oil pressure. Gasket height also was increased to provide higher contact pressure and better sealing. Costs were reduced 66% and sustainability was increased since the thermoplastic material is recyclable.

Category Winner: Process/Assembly/Enabling Technologies

Direct Exposure Laser Welding

OEM make and model: 2022 General Motors Co. Chevrolet Blazer
Tier supplier/processor: Magna Lighting
Material supplier/toolmaker: Various/SPM Automation
Material/process: Makrolon LED 2245 000000 PC/injection molding, laser welding

Hot-plate welding was replaced with a new process called direct epoxure laser welding to meet customer styling requirements for the light guides. Scanning lasers replace heated tools and can weld opaque lens borders without need for more costly laser-transparent materials. Additionally, clearance between internal components and weld ribs was reduced and ribs can be heated very precisely. The current design’s complex geometries would not have been possible with traditional welding processes. Additionally, scrap was reduced 40-50% and energy use by 85-95%.

Category Winner: Sustainability

Reclaimed TPO/Foam System

OEM make and model: 2020 General Motors Co. Chevrolet Silverado and GMC Sierra
Tier supplier/processor: Inteva Products LLC
Material supplier: Inteva Products LLC
Material/process: Inteather TGTPO ECO TPO/extrusion and repellitizing; co-extrusion of TPO sheets; vacuum forming and injection graining; press lamination; and assembly

Thanks to a patented recycling process, PIR bilaminate scrap comprised of TPO skins attached to cross-linked olefin foam is given new life in the same interior trim applications without sacrificing quality or performance. An additive package eliminates/binds/deactivates reactive residuals and trapped gases from foam. Just on this program, 680,389 kilograms of TPO resin is reclaimed annually, reducing landfilled scrap 93%, replacing 50% of prime TPO and lowering CO₂ emissions and energy use by 48% each.

Category Winner: Vehicle Engineering Team Award (VETA)

The winner of the VETA, the 2023 Cadillac Lyriq. Photo Credit: General Motors Co.

The all-electric 2023 Cadillac Lyriq and a team from General Motors Co. and its suppliers that developed the midsize sport utility vehicle (SUV) have been named the winners of this year’s Vehicle Engineering Team Award (VETA). The VETA award was created by SPE in 2004 to recognize the technical achievements of entire teams — comprised of automotive designers and engineers, Tier integrators, materials suppliers, toolmakers and others — whose work in research, design, engineering and manufacturing has led to significant integration of polymeric materials on notable vehicles. The vehicle features numerous plastic and composite innovations, many of which were nominated in other categories of SPE’s Automotive Innovation Awards Competition, including the following:

Aftermarket and Limited Edition/Specialty Vehicles Finalist: Electric Vehicle Supply Equipment (EVSE) Charging Accessory
Aftermarket and Limited Edition/Specialty Vehicles Nomination: Ultium Battery Charger
Body Exterior Finalist: Flow-Through Spoiler
Body Exterior Nomination: Front Headlamp System
Body Exterior Nomination: Rear Body-Side Taillamp System
Body Exterior Finalist: Front Enclosed Illuminated Grille
Body Interior Nomination: High-Gloss Piano Black Molded-in-Color (MIC)
Electric and Autonomous Vehicle Systems Nomination: Connection Ring for EV Motors
Electric and Autonomous Vehicle Systems Finalist: High-Damping AC Compressor Bracket
Materials Finalist: Dual Cordset EV Charger Lens
Materials Finalist: Thermal Management Tube & Connector Solution
Materials Nomination: Center Frame Panel
Process/Assembly/Enabling Technology Nomination: Elastic Averaging Vehicle Attachment
Sustainability Nomination: Recycled Resin Blow Molded Ducts

Category Winner: Hall of Fame Award

What is said to be the first mold in color (MIC) weatherable grille, used on the 1987 Volkswagen Golf, has been named the 2022 Hall of Fame Winner. The MIC weatherable grille, made possible with Luran S ASA from Ineos Styrolution (precolored plastic resins used in the plastic injection molding process so the molded part emerges in a specific color and finish), proved to be a game-changer for vehicle front grilles by providing a weatherable, paint free exterior surface.

To be considered for a Hall of Fame Award, an automotive plastic or composite component must have been in continuous service in some form for at least 15 years and broadly adopted in the automotive industry. This application certainly qualifies, as MIC grilles have become the industry standard used by every major OEM for front grilles replacing traditionally painted materials on more than 300 million exterior parts including grilles, mirrors, pillars, spoilers, fog bezels and more. Further technology now being developed around MIC ASA includes radar detection covers, lidar equipment and center high mounted stop lamp (CHMSL) bezels.

The companies involved in developing the MIC weatherable grille application include:

OEM: Volkswagen Group
Molder/processor: Volkswagen Group
Material supplier: Ineos Styrolution.

Representatives from these companies accepted the SPE Automotive Hall of Fame Award, on behalf of the original team that worked to develop the technology.

Category Winner: Lifetime Achievement

Probir Guha, who retired in 2021 after an illustrious career in the automotive composites industry (mostly with the Budd Company, Continental Structural Plastics and Coats), has been named the 2022 Lifetime Achievement Award winner by the Automotive Division of the Society of Plastics Engineers. Learn more about his career: “SPE Automotive Division announces 2022 Lifetime Achievement Award winner.”