Side Sill (Rocker Molding)
Automotive Award
Molder: Green Tokai Company
Moldmaker: Minco Tool and Mold, Inc.
Designer: Green Tokai Company
OEM: Honda
Description
The part is a Side Sill (rocker molding) that goes on the current Honda Odyssey van. The part has a Class “A” finish and an exact color match to the body. The color pallet has 9 colors.
Why is this Part Innovative?
If the materials and processes used are ecologically responsible, explain how: The key element of the part is the use of Green Tokai’s patented technology in the use of paint film. There are 3 stages of manufacturing the product: a) vacuum form process b) film trim process c)injection process. The use of paint film has greatly reduced the inventories (W.I.P.) that is required with a conventional painting operation. There is also a great benefit to society—the V.O.C. admissions are reduced by 98% in the manufacturing of the paint film over conventional painting. There are 0% V.O.C. admissions during the injection process. The product is 100% recyclable. Any scrap that is generated is not considered hazardous waste. With the use of paint film the consumer will get a product which is superior to conventional painting. The product performs much better in gravelometer and track testing of the vehicle for stone chipping. Side impact testing of the paint film also outperforms conventional paint. The color fastness of the product after 3000 hours if carbon arch testing shows a delta change of only <2.0. The consumer will have product that will not fade over the life of the vehicle.
Process
Gas Injection Molding was chosen to reduce warpage in part. Even packing throughout length of part. Relieve isolated stresses. Elimination of sink to produce a Class “A” surface/part.
Design
Design was done using CAD
CNC
Tooling
Steel
Injection mold steel
Vac & laser - aluminum
Number of Cavities: 2 cavity family mold (1+1)
Class "A" surface as molded
Material
TPO, Substrate and film was selected for economical and very good impact properties.
Finishing
N/A
