IAC Presents Weight and Mass Reduction Initiatives at 2009 ITB Automotive

published: September 24th, 2009
author: International Automotive Components

DEARBORN, Mich., Sept. 24 /PRNewswire/ -- International Automotive Components

(IAC) will discuss strategies and solutions for weight and mass reduction at

the 2009 ITB Automotive Cockpit and Door Conference today at the Sheraton

Detroit Novi Hotel in Novi, Mich. Lee Childers, IAC vice president, Advanced

Development and Tooling, will discuss IAC's strategy to help OEMs improve fuel

efficiency, by addressing the challenges associated with designing components

that help reduce vehicle weight. Childers' presentation is scheduled for 4:30

p.m.

"Weight reduction in vehicles continues to be one of the biggest issues facing

interiors suppliers," said Childers. "At IAC, we have already achieved

enormous successes in weight and mass reductions in vehicle interiors, but we

are committed to continue developing new products, materials and technologies

that can further reduce weight and impact fuel efficiency."

According to a study completed by the Environmental Protection Agency (EPA)

and Bureau of Transportation Statistics, 75 percent of fuel consumption is

directly related to vehicle weight, and EPA studies also have estimated that

reducing vehicle weight by 10 percent saves seven percent of fuel at the pump.

IAC's commitment to reduce weight and mass provides a potential weight

savings total of more than 40 pounds in an average, midsize vehicle. Door

panels, instrument panels, flooring and acoustics and headliners represent

significant opportunities for weight reduction.

"With IAC's current potential weight savings approaching 50 pounds, we are

working diligently with customers to provide solutions that confirm

efficiency," said Childers. "IAC's continued product, material and technology

developments will reduce costs, add value and offer intelligent fuel efficient

solutions to vehicles of the future."

The most significant weight reduction opportunity is exemplified in IAC's

flooring and acoustic segment with the use of bi-component fiber that combines

different fibers (e.g. polyester and polypropylene) within the same filament.

A 22 pound reduction could be achieved by using these recyclable, clean and

environmentally-friendly fibers that remain a part of the structure, add

integrity and offer a wide range of bonding temperatures for flooring and

acoustics applications. Bi-component fibers technology also features improved

sound absorption characteristics.

Additionally, part of IAC's lightweight strategy includes using natural fibers

(e.g. jute, flax, kenaf, sisal and hemp) blended with polypropylene to

configure door panels. With these two renewable materials, a one-step process

is possible and together the materials create a low-weight, high-impact

strength door panel. Potential weight savings in a door panel is nearly six

pounds using these material solutions.

Lighter cross car beams, spray polyurethane skin and thermoplastic olefin

(TPO) resin contribute to the weight savings opportunities available for

instrument panels. A combined solution could reduce overall instrument panel

weight by nearly nine pounds. The spray polyurethane skin delivers improved

craftsmanship, provides an excellent performance and durability and supports

the seamless passenger airbag design. The spray skin also has been approved

and accepted by several OEMs. Additionally, using TPO resin reduces material

density and improves performance while providing optimized weight and material

performance.

In headliner applications, IAC offers several solutions that could have a

potential weight savings of more than six pounds. These significant savings

include new technologies for lightweight materials and replacing metal

brackets with engineered resin for overhead lighting applications, all while

providing additional design flexibility, greater rigidity and optimum system

fit and finish.

ABOUT INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP

International Automotive Components Group is a leading global supplier of

automotive components and systems, including interior and exterior trim and

structural and functional applications. IAC operates manufacturing facilities

in 17 countries with more than 24,000 employees and 2008 global annual sales

in excess of $4.0 billion.

For more information, visit www.iacgroup.com