IAC Goes Blow Foaming for HVAC Component

Imagine a process for producing parts that cuts the weight in half and solves a sometimes vexing issue, in this case BSR, or buzz, squeak and rattle.

International Automotive Components (IAC), a supplier of things including interior parts and systems, is going to be using a new blow foaming process for producing HVAC ducts for a 2014 vehicle.

Essentially the process, which can be performed in slightly modified blow molding equipment, creates a lighter component thanks to the foaming action. In addition to which, it has better sound absorption qualities. IAC estimates that it reduces airflow noise in the ducts by as much as 30%.

In addition to which, because there is part consolidation, manufacturing costs are reduced. There is a 35% reduction in the amount of condensate compared with traditional blow-molded ducts, and there are improved thermal properties, as well.

While this is new to the North American market, IAC is licensing the technology from a Japanese company, JSP, which actually introduced it in 2002.

IAC says that the first year of production, which is going to be performed in its plant in Madisonville, KY, will be in excess of 100,000 units.

Other applications are being considered, as well.