8 Jul 2004
GE ADVANCED MATERIALS INTRODUCES HYDROPLAST™ STRUCTURES WITH UNIQUE SMARTLOK™ CONNECTION TECHNOLOGY
BREAKTHROUGH FRONT END MODULE SOLUTION OFFERS MORE EFFICIENT USE OF MATERIALS COMBINED WITH POTENTIAL INVESTMENT AND SYSTEM COST SAVINGS
BERGEN OP ZOOM, The Netherlands – June 29, 2004 – GE Advanced Materials, a division of General Electric Company (NYSE: GE), in conjunction with Carlisle Engineered Products and Vari-Form Inc., has developed an advanced Front End Module (FEM) technology that combines the strength of steel with the low mass of resins in a single cost-effective molding process.
Patented as HydroPlast™ Structures, the new FEM technology brings together pressure sequence hydroforming (PSH), with the established benefits of tight, reproducible tolerances, and the low-weight, high part-integration potential of GE Advanced Materials’ engineering resins. These benefits are obtained through the proprietary SmartLok™ Connection technology. The SmartLok™ Connection, formed in the injection molding process, is the integral tie between the metal and plastic enabling significant load transfer between the two materials.
According to Tom Goral, automotive technology manager at GE Advanced Materials, “In this application, the HydroPlast Structure complements existing production methodologies employed by many OEMs, who incorporate traditional plastic and metal front ends in their vehicles. More importantly, the HydroPlast Structure offers a new opportunity to produce modular front ends at a lower piece price and investment cost than its competition, while achieving weight-out objectives,” says Goral.
Proving the Concept
To provide the ultimate benchmark, GE Advanced Materials, Carlisle Engineered Products and Vari-Form undertook the development of the HydroPlast Structure FEM that met the OEM’s performance criteria. An existing sport utility vehicle (SUV) was used, which utilizes an all-metal front end that would yield the most comprehensive data to validate the HydroPlast Structure on a vehicle.
The starting point of the validation program was to benchmark the front end of the SUV into its component parts, to understand its structure in relation to its performance requirements. Next, a design was created and a tool built for the complete HydroPlast Structure injection molded part. The design integrates the radiator, bonnet (hood) latch, washer bottle, headlamps, grille and fascia, while managing both vehicle level input and local mechanical loads. A hydroformed insert combined with NORYL GTX® resin, a modified high-performance PPO/PA alloy, are the materials of choice for HydroPlast™ Structures.
Calibrated load tests were conducted on the HydroPlast Structure front end and on the original SUV with its all-metal front end. All tests conformed to industry norms and the OEM’s criteria. Criteria included mounting and torsional regularity, fixed first frequency, hood slam strength and durability, and hood latch retention.
HydroPlast Structures Versus Traditional Hybrids
Frank Mooijman, industry manager for bumpers and front ends at GE Advanced Materials, points out several advantages offered by HydroPlast Structures “With PSH, a closed section of steel is used to provide the stiffness required for FEM’s. The closed HydroPlast section is also a more efficient use of steel and plastic, eliminating stampings and the excess plastic used in competitive systems. The design efficiencies of HydroPlast could lead to savings on mass and cost”.
Mooijman adds, “Using proprietary pressure sequence hydroforming ultimately reduces the steel conversion cost in hybrid front end modules.
“Hydroforming is a known process that is trusted by automotive engineers for critical components such as engine cradles and roof rails. If you have a hybrid system comprised of multiple individual stamped parts, it requires investment in multiple metal dies. With PSH, only one die is required thus reducing investment cost.”
Mooijman notes the HydroPlast system can reduce tooling investment for the OEM by up to15 percent, and produce part cost savings of up to 10 to 20 percent. “Of course, the actual savings will vary from vehicle to vehicle and be dependent on type of construction used to produce the car.”
To bring HydroPlast Str
Reader enquiries
GE PlasticsPlasticslaan 1
4600 AC Bergen op Zoom
Netherlands
Helen Vandebovenkamp
helen.vandebovenkamp@ge.com
Tel: +31 164 29 20 97
Fax: +31 164 29 10 66
Netherlands
Notes for editors
Vari-Form
Based in Warren, Michigan, USA, Vari-Form is part of TI automotive limited, a privately held U.K. registered company. Since 1984, Vari-Form has produced hydroformed components for OEM’s around the world. Recognized as an innovator in the industry, Vari-Form’s patented Pressure Sequence Hydroforming (PSH) and hole piercing technologies have greatly expanded hydroforming design parameters, and has resulted in substantial cost savings for manufacturers. (www.vari-form.com).
Carlisle Engineered Products
Carlisle Engineered Products specializes in the design and manufacture of plastic and rubber automotive components. Carlisle Engineered Products has multiple processing capabilities: including injection molding, blow molding, thermoforming and extrusion. Carlisle Engineered Products has multiple plants in N. America and Mexico, and a joint venture in Europe named Lander Carlisle (www.cepcarlisle.com).
GE Advanced Materials
GE Advanced Materials is a world leader in providing materials solutions through engineering thermoplastics, silicon-based products and technology platforms, and fused quartz and ceramics. Among its businesses are:
• Silicones, which includes GE Toshiba Silicones in the Pacific region and GE Bayer Silicones in Europe, offers silanes, specialty silicones, urethane additives, adhesives, sealants, resins, and elastomers for a variety of industries such as personal care, automotive, tire and rubber, construction, healthcare, electronics, household and institutional, agriculture, textiles, appliances, bedding and furnishings, foam control, and consumer (http://www.gesilicones.com/gesilicones/am1/en/home.jsp);
• Plastics is a global plastics materials supplier and distributor, which serves customers in a variety of industries including aerospace, appliances, automotive, building and construction, data storage and optical media, medical, electrical and electronics devices, telecommunications, computers and peripheral devices, outdoor vehicles and devices, and packaging (http://www.geplastics.com);
• Quartz produces high purity materials for the semiconductor, fiber optic, lamp making and water purification industries. GE Quartz is a leading supplier of quartz materials to the semiconductor industry (www.gequartz.com/en/index.htm);
• GE (NYSE:GE) is a diversified technology, media, and financial services company dedicated to creating products that make life better. From aircraft engines and power generation to financial services, medical imaging, television programming, and plastics, GE operates in more than 100 countries and employs more than 300,000 people worldwide. For more information, visit the company's website at www.ge.com.
HydroPlast and SmartLok are trademarks of General Electric Company, Carlisle Engineered Products Inc. and Vari-Form Inc.
NORYL GTX is a registered trademark of General Electric Company.
Related images
Advanced Materials, in conjunction with Carlisle Engineered Products and Vari-Form Inc., has developed HydroPlast™ Structures, an advanced Front End Module (FEM) technology with unique SmartLok™ connections that combines the strength of steel with the low mass of resins in a single cost-effective molding process.
Editorial enquiries
Marianne Schouten
GE Advanced Materials
Brigitta de Vries
Marketing Solutions NV