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Ford 'chocolate' engine from Wales will help reduce weight
publication date: Apr 5, 2011
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author/source: Robin Roberts
Engine's being made by Ford in Bridgend incorporate "chocolate bar" technology in their plastic parts.
In their never-ending quest to reduce weight and therefore emissions and
fuel use, Ford engineers have taken inspiration from the Aero chocolate bar
to produce lighter plastic parts by injecting gas bubbles during man ufacturing.
There are many areas where weight can be saved by changing the type or grade
of metal used to a stronger, lighter material to trim kilos from the kerb
weight.
Plastic parts are an area where it is traditionally difficult to save
weight without sacrificing strength, durability or function, but Ford has found
a solution. MuCell technology introduces gas bubbles into the plastic as it is
moulded, leaving a microscopic honeycomb structure. |  |
These tiny spaces save
weight by reducing the amount of plastic used, without compromising the
integrity of the part.
Weight plays a key role in vehicle emissions and reducing the overall mass
of the vehicle results in improvements to fuel economy and carbon emissions.
Vehicle weights have increased in the last 30 years to allow for much greater
levels of equipment and radically improved safety attributes. Ford has targeted
reducing weight while still providing class leading levels of equipment and
5-star Euro NCAP safety ratings.
| MuCell brings a host of other benefits with lower pressures used to mould
the plastic and up to 33 per cent more parts per hour than a conventional
process. This increase in speed and efficiency reduces energy consumption,
manufacturing emissions and cost for parts produced using the innovative technique.
Ford's MuCell technology expert Carsten Starke is excited by the potential
of the new process: "The first time I saw this plastic under the
microscope I thought to myself it looks like an Aero chocolate bar! |  | The bubbles
in the chocolate change the taste, but in our plastics they save weight and
making cars lighter reduces emissions and fuel consumption significantly,"
he said.
"We are saving weight in many ways, not just by using this new plastic,
because lighter cars handle better, accelerate faster and stop more quickly.
For the customer it is win-win, the plastic is 20 per cent lighter without
increasing cost or reducing strength and it will help make their Ford better in
almost every aspect."
The MuCell technology will see its first application in engine covers on
vehicles such as Focus, C-MAX and Grand C-MAX, S-MAX, Mondeo and Galaxy in the
next few years. |
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