Thermoplastic Polyolefin meets requirements of FMVSS.
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Press Release Summary:
SEQUEL 2380® engineered polyolefin, suited for automotive interior applications, meets impact requirements of FMVSS (Federal Motor Vehicle Safety Standard) 201 and 208. With heat resistance to 110°C, product offers dimensional stability across broad temperature range. Uniform appearance is achieved by utilizing gravimetric blenders for color mixing at press, and material is resistant to buzz, squeak, and rattle produced by traditional interior materials.
Original Press Release:
New SEQUEL® 2380 Thermoplastic Polyolefin Provides Cost Savings, Durability, and Low-Gloss Appearance for Instrument Panel in GM Compact Pickups
All-TPO instrument panel is first for General Motors in North America
Auburn Hills, Michigan - The major components of the instrument panel in the Chevrolet Colorado and GMC Canyon compact pickup trucks are molded of SEQUEL® 2380 thermoplastic polyolefin (TPO). This new material has been developed by Solvay Engineered Polymers specifically for this type of application, and it is approved to the pertinent specifications at each of the North American Big Three automakers.
The instrument panel (IP) cover, which is the major visible surface of the IP, is molded by Intier Automotive. The glove-box door assembly and the driver's knee bolster are molded for Intier by NYX. Intier assembles and sequences the instrument panel for just-in-time shipment to the General Motors assembly plant that builds the two trucks in Shreveport, Louisiana.
Innovation driven by cost savings
This all-TPO panel in the Colorado/Canyon is the first of its kind for General Motors in North America. GM has similar applications in production in Europe. Traditionally, GM instrument panels have been built using painted PC/ABS parts or vinyl skin-and-foam construction. The unpainted TPO panel is a lower-cost alternative to both of these techniques, since it is molded with a grained Class A finish, eliminating the cost of secondary finishing operations.
For the IP cover, glove-box door, and knee bolster, SEQUEL 2380 TPO is delivered as a natural, and the parts are integrally colored at the press using a color concentrate supplied by PolyOne Corporation of Avon Lake, Ohio. The two colors in the program - medium dark pewter and very dark pewter - are achieved at concentrate letdown ratios of 50:1, a significant saving over typical ratios of 25:1.
The gloss level of the unpainted Colorado/Canyon instrument panel is measured at a level of four by industry standards, and this level can be maintained in high-volume production. "You can really see the grain on the surface because you're not filling it full of paint," points out Gary Kulhanek, the senior account manager for this application at Solvay Engineered Polymers. "The result is a more leather-like appearance and a look that has been described as 'frugally elegant' in an entry-level vehicle." He adds that the low-gloss surface also helps to eliminate reflections that can be a distraction to a driver.
Performance criteria drive material selection
SEQUEL 2380 engineered polyolefin was selected for use in these parts based on several of its performance properties. Perhaps most important for such an application, the material meets the impact requirements of FMVSS (Federal Motor Vehicle Safety Standard) 201 and 208.
The new TPO demonstrates excellent heat resistance at 110°C, the benchmark temperature for automotive interior applications. Dimensional stability across a broad temperature range is critical in a large part that is intended for snap-fit assembly. The Colorado/Canyon instrument panel is designed to achieve very tight gaps of 1 mm between the cover and adjacent trim parts such as the knee bolster.
SEQUEL 2380 polyolefin also exhibits extraordinary scratch resistance for a TPO. The new material meets a minimum requirement of 15 newtons in a re-engineered scratch test that is becoming a standard among automotive OEMs. Application of this level of force causes no visible whitening in the SEQUEL 2380 surface.
For all its structural stiffness and scratch resistance, this instrument panel has a softer feel than one molded in PC/ABS. The SEQUEL 2380 material is inherently resistant to the buzz, squeak, and rattle that can be produced by traditional interior materials. The elimination of acoustic materials or stand-off bumpers results in significant cost saving.
Process and environmental considerations
The use of SEQUEL 2380 in an all-TPO instrument panel system simplifies processing. The molder is able to use gravimetric blenders for color mixing at the press, achieving uniformly consistent appearance without streaking. The effects of in-plant damage are minimized by using a scratch-resistant TPO. While a tear in a foam-and-skin instrument panel would mean a fully scrapped part, SEQUEL 2380 is completely recyclable.
Experience, resources, and global support
Solvay Engineered Polymers, Inc., is the leading supplier of thermoplastic polyolefin (TPO) materials and technology to the North American automotive industry, with significant sales to European and Asian carmakers. The company is headquartered in Mansfield, Texas, with sales and marketing operations and an Automotive Applications Development Center in Auburn Hills, Michigan. Its manufacturing, distribution, and technology facilities are located in Mansfield and Grand Prairie, Texas. The acquisition of Thermoplastic Rubber Systems, Inc., in the first quarter of 2004 added development and manufacturing resources in Shirley, Massachusetts.
The production and engineering operations of Solvay Engineered Polymers are certified to the standards of ISO/TS 16949:2002 for quality systems. More information about its products and capabilities can be found at solvayengineeredpolymers.com.
Solvay Engineered Polymers, Inc. is a member of the Solvay Group, an international chemical and pharmaceutical group with headquarters in Brussels, Belgium. The Solvay Group employs more than 30,000 people in 50 countries, hi 2003, its consolidated sales amounted to EUR 7.6 billion, generated by activities in its three major business sectors: Pharmaceuticals, chemicals, and plastics. Solvay is listed in the Euronext 100 index of top European companies. For further information please consult: www.solvay.com.
Product information contact: Matt Binkinz
Interior Materials
Solvay Engineered Polymers
1200 Harmon Road
Auburn Hills, MI 48326
Phone: (248)391-5884
Fax: (248)391-9517
