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News

A new integrated door from Quadrant Plastic Composites

Quadrant EPP : 11 June, 2006  (New Product)
A new integrated door from Quadrant Plastic Composites hardware module, produced by the Ranger Group for Italian automaker, Lancia's Ypsilon subcompact
Passenger car, meets all European side-impact and hip-protection requirements with no foam pad, injectionmolded inlay, or other carrier reinforcement.
Additionally, Lancia was able to use a minimized steel bar in the door's outer skin. The module provides intrusion protection through clever design and high-tech, glass-mat thermoplastic composites from Quadrant Plastic Composites.

Integrated Door Hardware Modules Benefits & Challenges
Many types of integrated door-hardware modules (carriers) have been commercialized in the past 15 years, including allsteel, gas-assist injection-molded thermoplastic, long-fiberreinforced thermoplastic, and hybrid units combining
several material types. While these modules reduced a significant number of components and fasteners, lowered weight, and facilitated on-line assembly into the vehicle, they offered no additional occupant protection in a side-impact crash.

All automakers must meet intrusion-protection standards for the passenger or driver. But in Europe, there is also an additional hip-protection requirement to meet. Since there was no easy way to integrate this function into existing door module designs, a separate component, either a foam pad or injection-molded inlay, had to be installed. Ironically, this step added both weight and components, two of the features that door hardware modules were designed to reduce.

A Different Way to Build a Hardware Module Tier 2, Ranger Group set out to find a
better way to design and build an integrated door hardware module that would incorporate integral hip protection and other key features such as:

Multiple fixation holes & locators,
Screw domes,
Speaker & door-handle pockets,
Door-opening system guidance & fixations,
Wiring fixation and guidance, and
Window-opening system & guidance.

Ranger Group narrowed its materials search to 2 categories of composite materials, long-fiber reinforced thermoplastics and glass-mat thermoplastics, and designed aggressive test requirements for the materials to pass.
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