Ford is reducing costs 25% and improving reliability in a window lift carrier plate in the new Ford escape with an innovative two-shot injection molding process with overhead camming.
The process developed by Japanese Tier Two Hi-Lex uses a primary injection unit with a rotating mold plate in the moving half of the injection mold and a secondary injection unit integrated into the mold. First a polyacetal base is molded and then thermoplastic elastomer is overmolded with no hand transfer.
Ford superviser and technical expert Chester Wallawender says it’s believed to be the first time that polyacetal and TPE-C have been combined in a two-shot process to produce window carriers. The materials typically cannot be overmodled because TPE requires a mold temperature of 80ºF and acetal requires 160ºF.
The elastomeric material manages the shock of window open and close cycles as well as minimizing squeaks and rattles. Weight savings of the new process are approximately 10%.
The two-shot window lift carrier plate is a finalist in the Society of Plastics Engineers Automotive Innovation Awards program. Winners will be announced at a banquet in Livonia, Mich. Nov. 7.