Reduces part mass approximately 50 percent, provides improved NVH performance

SOUTHFIELD, Mich., June 6, 2011 /PRNewswire/ -- International Automotive Components (IAC) Group has introduced a new blow foaming process for HVAC duct components to be featured on a Model Year 2014 vehicle.  The proprietary process is patented and licensed from JSP, a global supplier of foamed plastics, by IAC Group for a customer program in North America.  

The innovative process and proprietary material utilizes existing blow molding equipment and requires minimal modifications.  IAC's manufacturing facility in Madisonville, Ky. will provide air ducts for the program, and annual volumes in the first year are expected to exceed 100,000 units.  Blow foaming is available for air ducts typically manufactured of high density polyethylene (HDPE) and has the potential to reduce mass by approximately 50 percent based on the application.

The blow foaming process provides multiple benefits:  

• It eliminates the need for secondary foaming pieces and reduces part count required in typical blow molding processes, thereby reducing manufacturing costs;
• It reduces BSR (buzz, squeak and rattle) and provides improved NVH characteristics due to its improved sound absorption properties, reducing  airflow noise by an estimated 30 percent when traveling through the duct;
• It achieves a 35 percent reduction in the amount of condensate over traditional blow molded ducts, and;
• It provides improved thermal properties, with less heat transfer than previous blow molded applications.

The inherent quieter acoustical characteristics of a blow foaming HVAC duct system addresses today's demand for quieter cabin interiors in light of the proliferation of hands-free communication devices and voice recognition systems used for vehicle navigation and infotainment.  

Blow foaming was introduced in Japan by JSP in 2002 and the arrangement for distribution and licensing in North America is exclusive to IAC for this program.  IAC sees significant opportunity with this solution, given its proven benefits and the opportunity to help customers reduce vehicle weight and part count, while achieving better product performance and saving manufacturing costs.  In addition to air duct applications, other vehicle applications are under consideration.  

ABOUT IAC GROUP

IAC Group is a leading global supplier of automotive components and systems, including interior and exterior trim.  IAC Group's 2010 sales revenue was approximately $3.7 billion. IAC has a geographically-diversified, efficient and low-cost global footprint with 75 manufacturing facilities in 16 countries.  The company employs approximately 22,000 people around the world.  IAC is headquartered in Luxembourg.  For more information, visit www.iacgroup.com.

SOURCE IAC Group

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