Teijin Group's Continental Structural Plastics (CSP) provides Ford Motor Company with the industry's first composite double-wall shock absorber hood for the 2020 Ford Explorer. This sheet-molded composite (SMC) advanced composite shroud significantly reduces noise, vibration and roughness in the cabin of the powertrain.
The composite hood was developed in cooperation with Ford, using tools in Ford's new NVH laboratory to create a space between the engine compartment and the steel front bulkhead by wrapping the rear of the engine and attaching to the pillars on either side of the engine compartment Air gap.
This composite double-wall shock absorber has many advantages over the all-steel components used in rival luxury SUV models. Acoustically, this composite material provides better sound barriers than competitive materials. The shroud also achieved a reduction in mass; at only 12 pounds, the four-piece assembly is lighter than a similar shroud stamped from steel. And because it's made of composite materials, it provides the formability and design flexibility needed to support complex inner-cover packaging environments.
Composite double-wall shock absorbers also reduce engine noise; improve acoustics by dissipating sound before reaching the main dashboard; provide superior thermal protection for electrical components; and take into account engine assembly and applicability issues.
Bryan Ludwig, CSP's director of business development, explains: "Composites are a great choice for many underlying applications because they have these properties and provide design flexibility. Because our fiberglass composites are a thermoset Material, which actually provides better thermal performance than metal and can be molded thin enough to fit in tight spaces in the engine compartment. "
CSP CEO Steve Rooney added, "We are always looking for ways to help our customers meet design and engineering challenges by using our composites. Ford is able to achieve a certain level thanks to the superior shock absorption provided by composites The cabin is quiet, which will enhance the driving experience for Explorer and Aviator owners. "
Double-wall shock absorbers are being produced at the Continental Structural Plastics Plant in Connaught, Ohio. The 190,000-square-foot facility is located in northeastern Ohio on 33 acres and employs 260 people. The plant will celebrate its 50th anniversary in 2019, making a range of structural composite parts for automotive and commercial customers.