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With a significant increase in awareness of safety and sustainability among the automobile original equipment manufacturers and end users, every car manufacturer is looking for lightweight, safe and cost-effective solutions for every unit present in their vehicle. The latter gets much more focus in developing countries, where the automobile market is extremely cost sensitive. Further, with implementation of the proposed global technical regulations on pedestrian safety in the near future and low-speed vehicle damageability requirements, demand for a low-cost, lighter and safer bumper system is ever increasing. This paper focuses on development of a unique thermoplastic energy-absorbing device for vehicle bumpers. Conventionally, major energy absorbing members of these bumper systems consist of three separate pieces: energy absorber, bumper beam and crash cans. A hybrid approach based on logical reasoning and topology optimization is used to conceive the design.

Automotive industry is looking for weight out options to increase the fuel efficiency of automobiles. Thermoplastics usage is increasing to reduce the dead weight of different automotive components. Traditional steering wheel can be replaced with thermoplastic to make it lighter without compromising its performance requirements. Thermoplastic steering wheel offers overall reduction in cost as well as significant reduction in mass. In addition, thermoplastic steering wheel also offers part integration and styling flexibility. As steering wheel has to meet variety of loading criteria (vibration, static loading, dynamic loading and fatigue), the overall design is a multi objective optimization process. Major challenges of thermoplastic steering wheel are to design the effective model for any particular wheel geometry domain defined by OEM's (Original Equipment Manufacturer) styling studios.

Automotive steering wheel (SW) is generally manufactured with metal armature and polyurethane / polypropylene (PU / PP) overmolding. The metal armature is used to provide structural stiffness and strength while PU / PP foam gives shape, touch and feel. Developed market use cast Magnesium or Aluminum as armature material, however emerging markets use steel for armature construction. With additional requirements (airbag integration, functional integration, aesthetics, compact and light weigh) being added to steering wheel, the steering wheel design is becoming more and more complex in nature. Thermoplastic SW offers competitive stiffness, impact, ductility and chemical resistance characteristics needed for the global automotive markets. A thermoplastic SW had been developed from a unique recyclable polycarbonate.

Improving passenger car damageability has been an important topic for The Insurance Institute for Highway Safety (IIHS) and the Research Council for Automotive Repairs (RCAR) council. Incorporation of new IIHS/RCAR barrier (Rigid bumper shaped barrier fitted with an energy absorbing material and cover) in ‘Bumper Structural Test protocols’ closely replicates the damage patterns observed in real world low-speed crashes. Inclusion of new IIHS/RCAR barrier impact (10kmph speed) test, along with IIHS and RCAR bumper test protocols, redefines the development of countermeasures for low speed damageability. In this paper an innovative cost effective, and lightweight, hybrid bumper beam solution is proposed with thermoplastics and steel, to meet IIHS and RCAR impact requirements including new IIHS/RCAR barrier impact test protocols.

Composite materials have found applications in the aviation industry because of an appropriate combination of properties - high stiffness, high heat performance and lower specific gravities. The Automotive industry has similar needs, and the application of composites in semi-structural application is a natural next phase. This is also necessitated because of global emphases on fuel efficiency and safety considerations in automotive applications. In this paper, thermoplastic composite material technology solutions and case studies for a number of applications, such as front-end-modules, door modules and instrument panel carriers are presented. Since processing and material modeling of composites is of critical importance in the design process, this paper also describes a new definition of isotropic properties of long glass composites, and perhaps the only way of honestly comparing such materials.

Basic concept of automobile steering wheel has been largely unchanged for years. A metal armature (cast Magnesium or Aluminum) is typically used for steering wheel in most of vehicles to provide stiffness and strength with an over-molded polyurethane giving shape and occupant protection. Thermoplastic steering wheel concept has been developed from a unique polycarbonate-based, recyclable thermoplastic. Thermoplastic steering wheel offers stiffness, impact and ductility performance needsed for the global automotive markets. It offers a green solution with mass and cost advantages. It also opens new avenues for design flexibility and styling differentiation. This paper presents thermoplastic steering wheel technology which optimizes the weight, processing complexity and performance.

Automobile manufacturers, designers, and cockpit system integrators are in constant search of solutions that reduce the number of interruptions across interior surfaces. Engineers require that this solution be efficient in terms of reliability, parts complexity, packaging space, and cost. The purpose of this paper is to describe the design and development of a cost effective, simplified seamless passenger airbag door system with an integrated chute for instrument panels. Through engineering thermoplastic material property advantages and scoring designs, this solution has a construction which may meet both styling and performance criteria while eliminating component parts such as a separate airbag chute, hinges, tethers, brackets, inserts, fabrics, and fasteners.

Basic automotive steering wheel armature design has been largely unchanged for years. A cast aluminum or magnesium armature is typically used to provide stiffness and strength with an overmolded polyurethane giving shape and occupant protection. A prototype steering wheel armature made from a unique recyclable thermoplastic eliminates the casting while meeting the same stiffness, impact, and performance criteria needed for the automotive market. It also opens new avenues for styling differentiation and flexibility. Prototype parts, manufacturing, and testing results will be covered.

Automobile manufacturers, designers, and cockpit systems integrators are in constant search for solutions in instrument panel designs that reduce the number of interruptions across styled interior contours. Eliminating the breaks across surfaces caused by functional seams or styling lines in traditional passenger airbag doors provides cleaner, more desirable interior aesthetics. Engineers require that this solution be efficient in terms of reliability, parts complexity, packaging space, and cost. The purpose of this paper is to describe the design and development of a cost effective, simplified-architecture seamless passenger airbag door system for instrument panels. Through engineering thermoplastic material property advantages and scoring designs, this solution has a construction which may meet both styling and performance criteria while eliminating component parts such as hinges, tethers, brackets, inserts, fabrics, and fasteners.