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Thermoplastic engineering materials are expanding in their uses for powertrain applications, ranging from decorative engine covers to intake manifolds and fuel rails. The search for more cost effective materials and reduced weight for these components continues. Hivalloy engineering resin alloys provide the necessary properties and performance required for powertrain applications and offer a variety of benefits versus traditional engineering thermoplastic materials such as nylon, acetal, and polyester products. In addition to significantly reduced weight and cost, other benefits include processability, as molded dimensional stability superior to traditional semi-crystalline resins, and reduced color shift due to heat aging.

Design of experiments results indicate that PPE foam is feasible for use in headliner applications. These results correspond to the current use of thermoplastic foams as headliner substrates in Japan and Europe. Thermoplastic foams offer many benefits for headliner applications. However, one concern has been with heat resistance and environmental cycling, specifically heat sag performance. To address this concern, a Design of Experiments (DOE) was completed on Polyphenylene Ether foam to understand how PPE content, foam density, thickness, and thermoforming compression effect heat sag performance for headliner applications. The DOE determined that for heat sag performance: % PPE and density strongly effect heat sag Thickness does not effect heat sag Thermoforming compression interacts with PPE content in its effect on heat sag. This paper will focus on the methodology behind the study and indicate optimum foam configuration for heat sag performance in headliner applications.

Two front seat base designs were developed using finite element analysis methods to meet automotive OEM requirements. The material-process combinations explored were injection molded VALOX® HS433 polyester resin and compression molded continuous glass reinforced AZDEL® PM10400 polypropylene composite material. The optimized seat bases weigh under two pounds and meet four automotive load-deflection requirements: Anti-submarining, ingress/egress, front crossbar and rear crossbar loads.