IMPAXX Block (figure 1)

IMPAXX Group (figure 2)

IMPAXX™ energy absorbing foam from Dow Automotive has been commercialized by DaimlerChrysler as a side impact countermeasure for the door of the newly designed smart fortwo. IMPAXX properties include superior crash performance at a cost effective price, and the product meets DaimlerChrysler’s specific requirements for the smart fortwo, which include providing occupant safety and comfort in up to 40 percent less packaging space(see figure 1).

Compared to other EA countermeasures like extruded polypropylene (ePP) or injection molded plastic parts, the IMPAXX parts weigh only 15gr, while offering the same technical advantages in energy absorbtion. Further, the solution meets the internal side impact requirements of the Mercedes Car Group and legally required standards such as the European ECE-R 95 and the US standard FMVSS 214.

Savings in weight and packaging space deliver additional benefits, such as reduced fuel consumption and greater design flexibility for in-door conveniences like larger door pockets. Furthermore, IMPAXX can be assembled to the door trim very easily by pushing it onto a cross rib feature without need for heat stakes, tape or adhesive (see figure 2).

Dow Automotive technical experts worked closely with DaimlerChrysler engineers in Europe during the early construction phase of the smart fortwo, enabling the development of a solution that achieved the target goals.

Dow Automotive provided DaimlerChrysler with comprehensive conceptual part design, CAD and CAE support including correlated material models and fast prototyping (the prototype parts were of production quality) helping to meet challenging vehicle development timeline. Last-minute design changes requiring no additional tooling costs and quick delivery of new parts are additional advantages achieved with IMPAXX.

IMPAXX energy absorbing foam and parts for this application are manufactured in Europe and delivered to the smart production site located in Hambach, France.

About Dow Automotive

Dow Automotive is a leading global provider of technology-driven solutions that meet consumer demand for vehicles that are safer, stronger, quieter, lighter, cleaner, comfortable and stylish. The organization provides plastics, adhesives, glass bonding systems, sealants, emissions control technology, films, fluids and structural enhancement and acoustical management solutions to OEM, tier and aftermarket customers around the world. For additional information about Dow Automotive products, services, and application development centers, visit www.dowautomotive.com.

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