AEI's What's New at SAE 2002
In-mold decorating
Gemini in-mold decorating from Serigraph Inc. is a multi-layered, in-mold decorating process targeted at supplanting the spray-painting process for plastic automotive parts and components. The construction combines in-register screen or offset printed graphics with the firm's proprietary adhesive, coating, forming, and in-mold technology. The resulting technology eliminates environmental concerns raised by spray painting, speeds up production, and lowers costs. Instead of shipping parts from molder to painter to assembler, the product enables simultaneous decoration and molding of the entire part and logos or graphics. Logos, colors, and other decorative or identification needs are screen or offset printed on a sheet of clear material, which is then laminated to another sheet or sheets of material. The resulting decorative surface provides almost bulletproof durability. The application is suitable for metallic looks and colors for telematics, GPS displays, lenses, and onboard entertainment systems.
3-D modeling
SolidWorks 3-D modeling software aids in completing product design quickly and accurately, and Microsoft Windows functions such as drag-and-drop, point-and-click, and cut-and-paste are easy to use. Users can create 3-D models from existing 2-D data with enhanced transition tools. Design communication capabilities are featured, including eDrawings, a breakthrough in sharing 2- and 3-D product design information. With the software, users can move components in a 3-D design and see how they physically interact with each other. Other drawing and part enhancements include exploded drawing views, the ability to split parts into associative models, and the ability to insert loft sections into an existing loft.
Oil-pan filtration
The all-plastic oil-pan-filtration system from SPX Filtran integrates different processes and components into one product. It is designed to provide a "fill for life" concept for transmission filtration. The modularized system provides almost 50% system weight reduction over replaced components, cost reduction due to reduced number of components and assembly steps, synchronization of components (six into one system), and improved quality control due to one supplier rather than six. The suction inlet position allows the customer to reduce ATF consumption substantially while reducing cavitation.
Test tools
Tadco Automotive AB, part of the XDIN Group in Sweden, develops automotive test and diagnostic tools, including a new series of test tools based on PDA's low-cost handheld computers. Applications are customized for each client's specific needs. Connection to industry standards (e.g., k-line, CAN, and MOST) is handled by cable interfaces with integrated protocol converters. Wireless Bluetooth communication is available.
Road wheel material
The first prototype road wheel using Thixomat, Inc.'s Thixo-molded component was developed in Japan in a joint effort between Japan Steel Works and an automotive OEM. The hub of the wheel is a Thixomolded magnesium alloy preform that is warm-forged to improve its structural integrity before it is fastened to the aluminum wheel body using chromium-plated steel bolts. The use of Thixomolding (>30% solids) was necessary to produce high-quality preforms with low porosity levels.
