The incorporation of Visteon independent rear suspension on the 2003 Lincoln Navigator reduced unsprung mass by 110 lb (50 kg).

The rear suspension on a full-size truck or SUV has typically been a beam-axle design, though not all companies follow this tradition. "This is the largest application of an independent rear suspension to date perhaps for any automaker, but definitely for Ford Motor Company," said Bob Walker, Engineering Director for Suspension and Exhaust Product Development for Visteon Corp. He was referring to the new 2003 Ford Expedition and Lincoln Navigator application, the independent rear suspension (IRS) providing ride and handling closer to passenger car performance.

Going to an IRS design, which makes Navigator and Expedition the first full-size SUVs with four-wheel independent suspension, resulted in about a 4-in (100-mm) lower floor tub than the previous solid-axle design. "The suspension has a Visteon torque arm, which allows for lower packaging height. And it provides for a floor depression which allows for fold-flat third-row seating," Walker said, referencing the optional power-operated feature, an industry first. (Visteon also did the seat, motor, and controls integration work on the power fold-flat configuration.)

Although IRS is not new technology, Visteon says the upsizing of the application is. The suspension on the vehicles now utilizes a 9.75-in (248-mm) ring gear, which is larger than the previous version. "There's a direct correlation in the amount of torque it can handle," said Walker. Towing capability is up to 8900 lb (4040 kg), when a 4x2 Ford Expedition is fitted with a 260-hp (194-kW)/350-lb•ft (475 N•m) 5.4-L Triton V8. The Lincoln Navigator has a tow rating of up to 8300 lb (3760 kg)—compared to the 2002 model's 8000 lb (3730 kg)—on 4x4 models and 8500 lb (3860 kg) on 4x2 versions.

The product development process lasted between 36 and 48 months, meaning work began prior to Visteon spinning off as a separate entity from Ford Motor Co. "This program started as a clean sheet of paper. It wasn't just a matter of 'make everything big' and it will work," said Walker, adding, "You don't want to take a car suspension and blow it up big." The vehicle's new rear suspension reduces rear unsprung mass by 110 lb (50 kg), which improves the suspension's ability to track uneven terrain, according to Ford.

- Kami Buchholz

VW Phaeton gets Valeo Double Xenon headlamps

Valeo developed the Double Xenon HID headlamp system for VW's Phaeton.

Valeo has developed a Double Xenon high-intensity discharge (HID) headlamp for the all-new 2003 European-market Volkswagen Phaeton. The lighting system uses two Xenon bulbs per headlamp: one for low beam and one for high beam.

"In each of the two Double Xenon headlamp units, one projector module provides low beam illumination while the second module delivers a powerful high beam. Each projector module is only 60 mm in diameter, and uses a ballast to convert dc to ac and generate high-voltage startup and significantly more power for maximum lighting efficiency," said Izumi Sakai, Product Manager of Valeo Lighting Systems.

Other Xenon headlamp applications have used either mono-Xenon for only the low beam or Bi-Xenon with the low and high beam in one module. In contrast, each Phaeton headlamp requires two ballasts and two Xenon bulbs.

"The optic surface—shape—of the reflector module is based on an elliptic surface, but it has been computerized to include the Valeo (Group's) know-how. The result is a complex surface," said Catherine Nicoli, Projectors Project Manager for Valeo Lighting Systems.

VW Phaeton's also uses a dynamic self-leveling system. The unit employs sensors positioned on the front and rear axles to communicate suspension compression rate information so that the headlamp beams stay in the optimum position.

"The Double Xenon is the most powerful automotive lighting system in the world," noted Dr. Falk Beil, Head of Electronics and Electrical Engineering for the Volkswagen Phaeton.

- Kami Buchholz

Aviator acoustically integrated by C&A

Collins & Aikman's AcTfiber for lightweight molded carpet systems is acoustically tuned by controlling fiber length, blended, and treated to increase densification where needed.

As the acoustic integrator for the 2003 Lincoln Aviator, Collins & Aikman decided to use its AcTfiber acoustically tunable fibrous material for carpet systems to meet specific vehicle sound management requirements. Officially introduced in 2001, AcT Technologies, a family of proprietary acoustically tunable products, are said to offer automotive manufacturers optimal acoustic performance coupled with significant weight and cost savings. According to Mike Mitchell, C&A's President of Global Commercial Operations, "AcTfiber, like our other AcT Technologies, offers customers a product solution engineered for 'custom tuning' in order to meet specific vehicle profiles."

AcTfiber is a blend of interlocked synthetic fibers custom tuned for sound transmission loss and absorption applications. In addition to being very cost competitive, C&A says AcTfiber provides a highly effective and efficient noise control solution and up to a 50% weight reduction as compared to alternative lightweight acoustic products. It can be customized to meet specific vehicle acoustic targets, is 100% recyclable, and offers a consistent level of performance throughout a vehicle's lifecycle.

Collins & Aikman's Technical Center in Plymouth, MI, is leading the development of AcTfiber, which is currently produced at the company's Old Fort, NC, manufacturing facility.

- Kevin Jost