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Panel 4: Innovative Materials

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1 Panel 4: Innovative Materials
Industry-First, Mold-In-Color, High-Gloss, High-Touch Black Resin for Automotive Interiors Robert D. Bedard Product Development Engineer Ford Motor Company May 21, 2014


3 Industry Trend Fusion/Mondeo A8/A4 1 Series/F20 Hyundai Sonata Corvette XJ/X351 High-Gloss Black interior finishes are popular in today’s vehicle themes

4 – Project Vision – utilize Mold-In-Color (Paint-free) Technology to achieve jewelry-like, high-gloss, solid-color automotive interior trim panels

5 This vision is aligned with Ford’s Primary Brand Pillars
Smart: Pleasing to the eye, and accentuates the interior theme & style. High-series appearance at affordable cost. Quality: Tough enough to withstand the rigors of repetitive contact, use, and the external elements Green: Manufactured without high-gloss paint, which is typically employed to make interior parts shine and to provide surface protection

6 – TECHNOLOGY COMPARISON – conventional vs. Next-generation

7 Conventional Technology
The conventional injection molding process leaves surface defects on the visible surface of the component, such as weld-lines and flow-marks Paint must be used to: cover these surface defects Achieve jet-black color, high-gloss, and deep, depth-of-image Weld-line Flow-mark

8 Conventional Value Chain for High-Gloss Paint
Resin Compounding Injection Molding Freight Warehousing at Paint Supplier Sub-assembly Clean-Room Paint Facility OEM Freight Long supplier chain, inefficient logistics, and scrap rate at paint shop all contribute to low, overall yield

9 – Innovations – Tooling design Material Science

10 Technology Breakthrough: Theory
A thermoplastic, in the liquid state, is injected into a mold. The thermoplastic then changes from a liquid state to a solid state, due to heat transfer into the mold’s walls. When a liquid thermoplastic is divided within the mold, the temperature at the front of the flow-front is higher than at the back of the flow-front. When two “cold” flow-fronts meet, a weld-line is produced. Solution: Control heat transfer by raising mold temperature as needed to reduce heat loss a* b* Knit Line visible to naked eye Knit Line invisible to naked eye *Advanced course on Applied Energy Engineering, Tokyo Tech OCW

11 Tooling Design Innovation
Electrically controlled heating elements are placed within the mold cavity to elevate the mold’s surface temperature above that which is used in conventional injection molding The cavity shell “floats” to enable efficient “heat-up” and “cool-down” phases of the molding cycle. The cavity shell is made of a special grade of stainless steel that provides both high thermal conductivity and high flexibility 1 3 1 2 2 3

12 Tooling Design Innovation
The heating elements within the cavity reduce flow-front heat loss, allowing the thermoplastic to flow and knit homogeneously within the injection mold. The elements are organized into zones, which govern heat delivery to respective regions within the cavity. A controller unit is used to tailor the amount of heat delivered to each zone, based on the amount of heat required to achieve exceptional surface finish for complicated component geometry.

13 Tooling Design Innovation Conventional Cooling Method
New Cooling Method A B A Water flows through a “circuit” to stabilize the temperature of the mold’s core B Heat is rapidly extracted from the mold’s core through contact with a specially designed “cooling plate”

14 Material Science Innovation
Ford Motor Company and BASF Corporation partnered to develop an all-new polyamide resin used to manufacture the Fusion’s four door trim panel switch bezels; this was the automotive industry’s first application of paint-free, jewelry-like, jet-black trim panels located within interior high-touch zones This paint-free material science innovation was achieved via the following enablers: the use of exotic additives, optimization of the polymer formulation, and the use of specialized colorant packages Approximately 75 different iterations of additives, polymers, and colorants were extensively tested to hone in on the final formulation, in order to deliver depth-of-color and to meet durability requirements BEFORE AFTER NOTES TO SELF, FOR TALKING POINTS: Show that MIC resin must balance very different requirements…very complex chemistry Show what a grained part must do, and how this is much different than a high-gloss, un-grained part Key Message: Cost and green savings, with outstanding aesthetics & quality…impact, UV, mar, temperature/humidity, also had to be considered…money savings to Ford and revenue for BASF, and the customer gets a nicer interior for the price – value! FOR COMMENT ONLY: What’s next? Metallic Colors Fiesta, Edge – Celanese – POM – Already in production

15 benefits

16 Technology enables a Paradigm Shift across the entire Value Chain
Component Design Material Science Tooling Technology Molding Technology Pre-2011: Jewelry-like Painted Finishes Post-2011: Jewelry-like Mold-In-Color Finishes Long Supplier Chain Creation of VOCs & CO2 High Scrap Rate High Hidden Factory costs Shortened Supplier Chain Mitigation of VOCs & CO2 Low Scrap Rate Reduced Hidden Factory costs

17 Conventional Molding + Pigmented Base Coat & Clear Top Coat
Smart Ford Fusion Door Switch Bezels High-Touch, High-Gloss Black Mold-In-Color 36% COST AVOIDANCE! Mold-In-Color Conventional Molding + Pigmented Base Coat & Clear Top Coat

18 Smart “The Tip of the Iceberg” More opportunities exist
across entire vehicles Approximately 40% savings per Fusion, Mondeo door bezel Several million dollars of incremental revenue generated per Fusion, Mondeo Future Opportunity: Forecasted Global Annual Volume: approximately million units Future Opportunity: Millions of dollars of revenue generated annually, per additional Ford components

19 Quality Mitigated paint-introduced quality defects like loss of adhesion, orange peel, dirt-in-paint, dry spray, etc. Strengthened product appeal in marketplace. For example, J.D. Power & Associates APEAL Study stated:

20 Green Mitigated Volatile Organic Compounds (VOCs) and Carbon Dioxide (CO2) created by paint process Reduced CO2 emissions due to stream-lined Value Chain. An estimated 60,000 pounds of CO2 are mitigated annually from Ford Fusion production. Eliminated paint waste from entering landfills Improved health & safety via mitigation of exposure to harmful paint chemicals

21 High-Gloss Mold-In-Color Applications in Development
plastics_blau_weiss.pot High-Gloss Mold-In-Color Applications in Development Ford Mondeo Ford Figo Ford Edge

22 2014 Automotive News PACE™ Innovation Award for Material Development
Recognitions 2014 Automotive News PACE™ Innovation Partnership Award 2014 Automotive News PACE™ Innovation Award for Material Development

23 Materials Category Finalist with BASF Corporation, 2012
Recognitions Materials Category Finalist with BASF Corporation, 2012 US Patent Office, 2013 & 2014 On-line Publication, 2013 On-line Publication, 2013

24 Our Team Ford Motor Company: Engineering, Design, Development, & Testing H. M. Sun, M. Masserant, C. Boese, R. Bedard, D. Woods, C. Nielsen BASF Corporation & Americhem, Incorporated : Resin & Colorant Development J. Leptich, H. Cowell, S. Tupper, S. Windahl, S. Hanley, T. Patel, B. Myers Michael Tool & Mold, Synventive Molding Solutions, CUMSA: Tooling M. Graf, J. Sulaiman, A. Hui, R. Cilia, R. Long, S. Navarra, J. de Fortuny NADA Innovation: E-Mold Technology M. Kang, D. Lee, K. Shin Summit Polymers, Incorporated: Manufacturing P. Bassett, K. Klimach, S. Crandall, K. Bulifant, M. Lazor, T. Loc

25 QUESTIONS & answers

26 Thank you!


28 Technology Evolution 2012 Ford Escape – High Gloss 2013 Ford Escape –
Large Screen TVs Automotive Interiors 2012 Ford Escape – High Gloss Home Appliances 2013 Ford Escape – Low Gloss Note: Pre-2011, TV frames were painted. Technology migrated from consumer electronics to automotive. Ford leads in the automotive industry.

29 Technology Benchmarking: High-Gloss Black Finish Panels

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