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 Plastics - Consumption in Automobiles

 Future Trends In Indian Automotive Industry

 Interior & Exterior Applications

 Pillar Trims

 Floor Consoles

 Door Panels/ Door Modules

 Instrument Panels/ Cockpit

 Attachment Methods

 Over Head Systems

 Ergonomics Basics

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PP & Alloys 57.7 943000
PUR 18.1 296000
ABS & Alloys 9.5 155000
PE 10.3 168000
PA & Alloys 15.6 255000
PVC 3.7 60000
PBT+PET 3.1 51000
UP 1.9 31000
Others (PC, PMMA, POM, PPE, SM, PF,
13.2 216000
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This plastics consumption (2003) in European Union (27 countries) only figures the
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Bumpers PP, ABS, PC 10.0
Seats PUR,PP,PVC,ABS,PA 13.0
Dashboard PP,ABS,PA,PC,PE 15.0
Fuel Systems PE,POM,PA,PP 07.0
Body (incl. body panels) PP,PPE,UP 06.0
Under the bonnet comp. PA,PP,PBT 09.0
Interior trim PP,ABS,PET,POM,PVC 20.0
Electrical components PP,PE,PBT,PA,PVC, 07.0
Exterior trim ABS,PA,PBT,ASA,PP 04.0
Lighting PP,PC,ABS,PMMA,UP 05.0
Upholstery PVC,PUR,PP,PE 08.0
Other reservoirs PP,PE,PA 01.0
Total 105.0

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10386130 (RH) 10377668 (LH)
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11509231 10396621 (LH) ANB50021 (LH) CLIPS COVER
(QTY- 61) 10396622 (RH) ANB40014 (RH) 16754704 ANB40004 (LH)
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Abbrevations
HLU Hand Lay UP
RIM Reaction Injection Moulding
MT Stampable Thermoplastics
IM/BMC Injection moulding ( Bulk moulding Compound)
RTM Resin Transfer Moulding
UP Unsaturated Polyester
VE Vinyl Ester
PU Poly urethane
EP Epoxy
MF Mineral Filled
CSM Chopped strand Mat ( lass)
SMC Sheet Moulding Compound
CS Chopped Strands ( lass )
LCP Liquid Crystaline Polymers
PI Polyimides
PTE Polyester Thermoplastic Elastomer
PPE Poly phenyelene ether
MPPO Modified Poly Phenylene Oxide
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The function of the headliner over the past years has

evolved from merely a "liner³ to that of a vital player in both





and
 

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respectively.

The headliners today are a sandwich of many different

materials that are combined in order to enhance these
properties

Enhances appearance
Conceals roof structure
Promotes interior harmony
Feels good (soft)
Avoids odor
Avoids fogging

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 Sunroof
 Moon roof

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RAB CUTOUT FOR

HANDLE `C¶ PILLAR
CUTOUT

CUTOUT FOR
`B¶ PILLAR
CUTOUT FOR
`A¶ PILLAR

CUTOUT
FOR
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CUTOUT
FOR VIOSR

CUTOUT FOR
RECEPTACLE

CUTOUT FOR
BEZEL
CUTOUT FOR
MAP LAMP

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From the design point of view, only 3 surfaces are considered;

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The fabric side or Interior show surface.
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Surface from the back side of the fabric to the laminated blank outer surface.



Top most surface which is closest to the sheet metal (Roof) and is opposite the
A surface
  


The side wall of boundary and internal cutouts. This surface is part of A or C
surface from CAD file point of view `C¶
SURFACE
CLOSIN
SURFACE

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SURFACE SURFACE

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COVER
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The main component for binding other materials to itself. known as the high
strength board under the basic construction of chopped glass, adhesive, and
PET scrim.

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The material which makes up the outermost aesthetics
(fabric) and is mated with the laminated blank on the 2nd surface. This material is
usually made up of fabric +foam +adhesive (tri-laminate).
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COVER
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Comes in many types with base thread of either Polyester or Nylon.

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A material normally found on the C surface of the formed substrate which can assist
in the ability to attach components and provides protection from human contact
against the fiber glass.
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Material which bonds the substrate to the fiberglass to the scrim to the cover goods.
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The deviation from initial installed position to the final position after complete
environmental cycling.

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The ability of the fabric to withstand a 180 degree pull from the formed
substrate.

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Ability to absorb sound from varying sources such as roof panel noise, road
noise, engine noise, and BSR¶s.

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The ability to not have materials gas out and leave deposits on the interior
glass.



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Must comply with government regulations for flame propagation.

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FOLLOWIN ARE THE SUB-SYSTEMS WHICH FORM PART OF

OVERHEAD SYSTEM:
 OVERHEAD CONSOLES
 VISOR ASSEMBLIES
 RAB HANDLES
 MAP, DOME AND COURTESY LAMPS
 HEAD IMPACT MANAEMENT (HIC)

ADDITIONAL SUB-SYSTEM:
 SIDE IMPACT AIRBAS
 HVAC
 CONVENIENCE ELECTRONICS INCLUDIN:
 INTRUSION SENSOR
 REAR PARKIN ASSIST MODULES
 VIDEO ENTERTAINMENT SYSTEMS

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Worm tracks are groove/channels running on the c-surface of a headliner.

Worm tracks hold the wire harness routing in place
The wire harness is glued on these tracks
Worm tracks are beneficial for allowing clearance to the roof steel, by taking
some depth from wires
Worm tracks are used as locators also for Foam pads

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HIC stands for Head Injury Criteria. The HIC number is a relative
measure of experimental data to a critical head injury threshold for
blunt impact.
HIC is a numerical value dervied from the following formula;
The formula for HIC of the FMH (free motion headform) is

but the spec. is for HIC(d) or the dummy equivalent of HICfmh

HIC value should not exceed 1000 as per safety regulations.

HIC pads are protective padding between the headliner and vehicle
roof, which provide a cushioning effect for occupants head, in the event
of a crash.

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‡ ACOUSTICOR
‡ POLYBOND
‡ THERMOBOND

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ROOF RAIL
REAR

ROOF
BOW

RAIL
ROOF RAIL SIDE ROOF
FRONT

A PILLAR B PILLAR REAR

INNER
PANEL

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‡ X ±Axis runs vertically through the

vehicle front to back
‡ Positive X coordinate is to the
rear of the vehicle
‡ Negative X coordinate is to the
front of the vehicle

‡ Y - Axis coordinate is a point left

or right of the centerline
‡ Positive Y coordinate is left of
the centerline
‡ Negative Y coordinate is right of
the centerline

‡ Z ± Axis Runs perpendicular to

both X and Y planes along the
height of the vehicle
‡ Positive Z coordinate is closer
the roof of the vehicle
‡ Negative Z coordinate is nearer
the floor of the vehicle
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‡ Intersection of all three planes

‡ 0X, 0Y, 0Z coordinate

‡ OEMs locate point of origin in

different places
‡ Center of front bumper
‡ Center of the firewall
‡ Point where the middle of the
wheel and rocker panel meet

‡ Know the point of origin to

ensure proper use of coordinates

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‡ Prints and drawings are two-dimensional, so different views must

be used to properly show a point
‡ X-Z shows location along length and height
‡ X-Y shows location along length and width
‡ Y-Z shows location along width and height

All three are necessary O[r

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‡ rid lines are formed by intersection of planes

‡ rid lines are at 100 millimeter increments
‡ rid lines help package and locate objects and spaces
‡ Work lines are located on individual parts
‡ Used to lay out parts and project views of parts at different angles
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‡ Body position is where a part is located with respect to

the body
‡ X and Y coordinates in two dimensions
‡ X, Y and Z coordinates in three dimensions
‡ Commonly called ³in body´ or ³in vehicle´ position
‡ Design position is point of view you draw the part from
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‡ Other terms used to describe locations

‡ Centerline
‡ Left Hand and Right Hand
‡ Inboard and Outboard
‡ Fore and Aft OÎO


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‡ Many locating points are used to define

occupant¶s location in a vehicle
‡ Eyellipse
‡ Seating Reference Point
‡ H-Point
‡ D-Point
‡ Accelerator Heel Point
‡ Hand Reach Envelope

‡ Critical for developing safe, comfortable seat

systems
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‡ Statistical representation
of the driver¶s eye location
in the vehicle
‡ Eye range is an ellipse

‡ Eyellipse must allow for

clear view inside and
outside the vehicle

‡ Starting point for vehicle

design
‡ If the driver can¶t see
properly, vehicle is not safe

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‡ Based on eyellipse location

so occupant is properly
positioned in vehicle
‡ Measured from intersection
of line down from mid-eye
centroid and projected back
and hip angles
‡ Referred to as SgRP

‡ Becomes the origin for

defining design H-Point

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‡ Establishes the rearmost normal design driving

or riding position for each designated seat

‡ Considers all modes of adjustment

‡ Horizontal, vertical and tilt

‡ OEM provides SgRP and

‡ Foot angle
‡ Knee angle
‡ Heel point
‡ Hip angle
‡ Back angle
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‡ SgRP, torso angle and hip point, define

‡ Location of eyellipse in vehicle
‡ Wiper pattern
‡ Defrost pattern
‡ Seat belt zones
‡ Airbags and knee blockers
‡ Hand reach envelope

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Oscar is used to measure seating accommodations

‡ Oscar template is two-dimensional
‡ Oscar machine is three-dimensional
Shows designers how occupant will sit in seat
‡ Helps determine design H-Point, the pivot point of thigh and torso
‡ Design H-Point should match SgRP Oη
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D-Point
‡ Lowest point on the buttocks contour on Oscar
‡ Measures how far the occupant sinks into the seat
‡ Used to avoid hard point sin the seat that may make the occupant uncomfortable
‡ Helps determine foam thickness and suspension type

Accelerator Heel Point 87o minimum

‡ Refers to Oscar¶s heel point with shoe on un-depressed accelerator
‡ Altering heel point affects comfort and safe operation of foot controls
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‡ Reaching distances for specific driving populations define and

envelope´ into which primary and secondary controls should be
located

‡ Reaching distance depends on elevation of the control from H-Point

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‡ Driver position is defined by several

measures
± Eyellipse represents field of vision
± Eyellipse helps define seating reference
point, or SgRP
± SgRP becomes basis for defining design H-
Point
± Design and actual H-Point are measured
using two- and three-dimensional Oscar
templates and manikins

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