2007-11-21 Manufacturing News

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Automotive supplier uses molding and polymers combo for Opel sunroof

Global tier one automotive supplier ArvinMeritor specified materials from Ticona when using special outsert molding for the Opel Astra sunroof system.

ArvinMeritor Sunroof Elements Use Outsert Molding and Ticona Polymers to Cut Cost, Gain Performance. Global tier one automotive supplier ArvinMeritor specified materials from Ticona, the engineering polymers business of Celanese Corporation, when innovative outsert molding was chosen to reduce the cost and improve the performance of a sunroof system it developed for the Opel Astra Caravan**.

The sunroof’s sliding tracks and air deflectors, molded by the TB&C Outsert Center in Herborn, Germany, use Hostaform* acetal copolymer (POM) and Celstran* long fiber-reinforced thermoplastic (LFRT). The outsert molding method and Ticona engineering plastics deliver sophisticated parts high in precision and integration. This method also significantly cuts costs versus conventional production methods by reducing the number of components to be assembled by up to two-thirds.

Sliding tracks use Hostaform* acetal copolymer (POM) and Celstran* long fiber-reinforced thermoplastic (LFRT). Click Here for High resolution image. photo: TB&C Outsert Center

Outsert molding consists of injection molding functional plastic elements like expanding pins, centering domes and guides on metal base plates. These elements are anchored via holes and undercuts. By contrast, insert molding, the other major process for creating metal-plastic parts, overmolds metal parts placed in an injection mold.

Outset molding enabled the ArvinMeritor operation in Dietzenbach, Germany, to develop this sunroof with sliding tracks that consist of a stiff metal base and injection molded guides made from Hostaform POM, which offers outstanding sliding properties and low wear. Hostaform C 9021XAP M POM ensures smooth sunroof operation with molded-on sliding tracks that meet 0.05-mm tolerances at temperatures from -40° to 120°C.

Air deflector uses high heat distortion temperature of Celstran* long fiber-reinforced thermoplastic (LFRT), which makes it highly compatible with metal during processing. Click Here for High resolution image. photo: TB&C Outsert Center

Outsert molding also was used in the air deflectors, the first time a net was integrated into a part by this molding method. Using the high heat distortion temperature of Celstran LFT, which is highly compatible with metal during processing, TB&C Outsert Center overmolds nets and metal profiles placed in an injection mold. This method produces air deflectors that are ready for installation on the automotive as they come from the mold because it eliminates post-trimming, deflashing and other costly operations.

The TB&C Outsert Center is a spin-off from the Philips Group based in Herborn, Germany. Its product portfolio consists of high-precision multi-part composite components – mainly metal and plastics – which are produced by innovative outsert molding technology. TB&C develops and manufactures assemblies for the following sectors: the automotive industry, medical technology and other industrial applications. The assemblies range from car door modules and sunroofs to printer components and electromechanical assemblies for the medical device sector. Since 2004, the TB&C Outsert Center, which employs some 120 people, has belonged to the international group, Te Bokkel & Company (TB&C).

ArvinMeritor, Inc., Headquartered in Troy, Mich., USA is a premier global automotive supplier of a broad range of integrated systems, modules and components to the motor vehicle industry. The company serves light vehicle, commercial truck, trailer and specialty original equipment manufacturers and certain aftermarkets.

* All registered trademarks are owned by Ticona or its affiliates.
** Astra Caravan is a trademark of Adam Opel GmbH

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