||Metal to plastics conversion of clutch pedal support.
Weight savings: 1 lb (57%). Cost
savings: $5 per assembly.
|Most Innovative Feature:
||Weight Saving from Metal 800 grams to Plastics 346 grams
(Total Saving = 1 lbs.)
|Other Innovative Features:
||Estimated Cost Saving of € 5,- Euro per assembly due to
design advantages in long glass fiber plastics.
|What Forming Process?
|First Time Process Used:
||Replaced Metal Part Assembly, which was cut, bend, welded,
||No extra tooling innovations needed to produce LGF-Material.
That's an advantage!
|New Material Developments:
||Patented Pultrusion process of long-glass fiber plastics
material by GE Plastics- LNP, named
||From 800 grams (1.76 lbs) to 346 grams (0.76 lbs) = 454
grams (1 lbs.) Weight Savings.
||€ 5 Euro/Assembly (equals to 5 USD/Assembly)
||Reduced Assembly time. Integrated Bayonet Lock (plug and
turn) of master cylinder. This way you spare 4 bolts and nuts and the
assembly time for that.
|Direct Consumer Benefit:
||No direct benefit.
|Translates to Other Vehicles?:
||Highly translatable to all manual gear shift cars. Modular
use for several car platforms. For Automatic transmission you can easily
leave this part out.
||Master Cylinder is hidden/protected inside Clutch Support.
Support is symmetrically loaded by master cylinder.
||Ease of disassembly and recyclable materials used.
||Long glass fiber VERTON MFX 700-10 HS is capable of
withstanding load testing of:
- 450 Newton side load at
pedal – no break
- 1500 Newton “in plane”
load at pedal – no break