This month, Magna won three first prizes at the 2018 Plastic Engineers Association (SPE) Car Awards ceremony in Düsseldorf, Germany. In recognition of the innovative lightweighting efforts of its advanced materials, Magna's 2019 Jeep Cherokee thermoplastic lift doors have earned the body appearance category. Its carbon fiber sub-frame prototype won the chassis category; its torsional welding connection process won in the support technology category.
The lightweight, fully recyclable compound liftgate is as advantageous as all 2019 Jeep Cherokees, as the global demand for crossovers and sport utility vehicles remains high. Compared to the steel version, these lift modules save up to 25% in quality and are delivered to the customer as a complete component. Composite materials offer greater design flexibility, deeper stretch and a more compact radius. Other advantages of Magna's full system assembly and delivery methods include reducing the complexity of the entire liftgate module, reducing tool investment and increasing assembly plant throughput.
The carbon fiber, which also won the infinite market growth award CAMX 2017, is the result of a continuous joint R&d project, Ford Motor Company. By replacing 45 steel parts with two molded parts and six steel parts, the prototype sub-frame was reduced by 82%, saving 34% compared to the sub-frame made of stamped steel. Vehicle level testing is currently underway.
Torsion welding joins the plastic brackets to the thermoplastic panels and uses high-speed torsional motion to create enough frictional heat to fuse them together. Magna worked with technology partners to become the first company to use reverse welding for automotive dashboards. The process is currently used in the front panel of Skoda Octavia in Europe in 2017 and is planned to be used soon in the North American market.
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