Jeep Wrangler Header Bow

Chrysler Jeep Wrangler

Problem: In developing a new structural “header” component for a major automotive OEM, first tier part supplier Decoma Kinetex wanted to substitute reinforced plastic for a hybrid part which encased a steel rod in a reaction injection molded (RIM) foam material. The RIM material was prone to chipping and cracking, and the existing header part was thought to be too expensive.

Solution: Decoma and CPI Binani cooperated in the design and development

Jeep Wrangler Header Bow Made by CPI Binani’s Advantage™ Technology

of a header based on CPI Binani’s DFT (Direct Feed Thermoplastic) process for formulating LFT (Long Fiber Thermoplastic) composite parts. The DFT process involves in-line compounding of resin and reinforcement, coupled directly with compression or transfer molding to form a finished part.

Results: CPI Binani and Decoma were able to develop a part made of fiber-reinforced polypropylene with short steel inserts at each end.

The ribbed part design and glass/PP formulation was stronger than the existing steel-RIM hybrid part and cost about 40% less to make. The redesigned header and two door surround parts – also made using CPI Binani’s process – provide a strong, reliable soft-top structure.

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