Cowl

Purpose/Function: 1. It is a projected from dial to restrict external light beams falling on dial of instrument in the instrument cluster. 2. It prevents cluster form dust entry and water entry inside the cluster. 3. Cowl is mounted on instrument cluster either by fastening screw or by snap fit arrangement. Possible Modes of Failure: 1. Mismatching of fitment holes 2. Damage \ breakage of snap fit legs. 3. Warpage in cowl. 4. Weakening of cowl walls. 5. Plastic defects such as flash, shrinkage, warpage etc. 6. Loosening of cowl on the housing. 7. Failure at fitment areas. Design Procedure: 1. Determine thickness depending upon strength requirement of cowl. 2. Provide minimum thickness as possible to ensure faster cooling rate, less material consumption and more productivity. 3. Provide uniform thickness to all sections of the cowl to ensure uniform cooling and prevention of plastic defects. 4. C.D. of mounting holes on cowl should match with C.D. corresponding holes on the housing. 5. Snap fit legs should be designed based on the principles of cantilever beams. 6. The cantilever beams should be broader at the base with taper ratio of 1:1.25 to 1:.5. 7. Provide corner radius at the base of snap legs to avoid breakage at the base. 8. Consider all the plastic defects such as shrinkage, warpage, flash etc. while designing of cowl. Material: 1. Polypropylene 2. ABS

Properties of Material:
POLYPROPYLENE MOLDED PHYSICAL PROPERTIES Density Water Absorption Moisture Absorption at Equilibrium Moisture Vapor Transmission Oxygen Transmission Environmental Stress Crack Resistance Linear Mold Shrinkage Melt Flow Hardness, Rockwell R Hardness, Shore D Tensile Strength, Ultimate Tensile Strength, Yield Elongation @ break Elongation @ Yield Tensile Modulus Flexural Modulus Flexural Yield Strength Compressive Yield Strength Izod Impact, Notched Izod Impact, Unnotched Izod Impact, Unnotched Low Temp Izod Impact, Notched Low Temp Charpy Impact, Unnotched Charpy Impact, Notched Low Temp Charpy Impact, Unnotched Low Temp Charpy Impact 0.0325-0.0448 lb/in3 0.01-0.1 % 0.10% 23.9 cc-mil/100 in-24hr-atm 241 cc-mil/100 in-24hr-atm 1000 hour Min. 0.006 in/in 0.5-136 g/10 min MECHANICAL PROPERTIES 70-113 68-83 2860-11600 psi 1740-6240 psi 3-887 % 3.5-110 % 72.5-1100 ksi 79.8-350 ksi 3450-7250 psi 6820-7250 psi 0.3-NB 12-31.1 ft-lb/in 4.96-40.1 ft-lb/in 0.506-2 ft-lb/in 6.66-NB 0.619-80.9 ft-lb/in2 3.81-109 ft-lb/in2 0.952-45.2 ft-lb/in2

Gardner Impact Low Temperature Gardner Impact Tensile Creep Modulus, 1 hour Tensile Creep Modulus, 1000 hours Electrical Resistivity Dielectric Constant Dielectric Constant, Low Frequency Dielectric Strength Dissipation Factor Dissipatin Factor, Low Frequency Surface Resistance Arc Resistance Comparative Tracking Index CTE, linear 200 C Heat Capacity Thermal Conductivity Melting Point Maximum Service Temperature, Air Deflection Temperature at 0.46 MPa Deflection Temperature at 1.8 MPa Vicat Softening Point UL RTI, Electrical UL RTI, Mechanical with Impact UL RTI, Mechanical without Impact Flammability, UL94 Haze Processing Temperature Rear Barrel Temperature Middle Barrel Temperatue Front Barrel Temperature Nozzle Temperature Mold Temperature Drying Temperature

0.885-21.8 ft-lb 8.11-35.4 ft-lb 79800-102000 psi 31900-63800 psi ELECTRICAL PROPERTIES 1E+14-1E+17 ohm-cm 2.2-2.3 2.3 559-3560 kV/in 0.0002-0.002 0.00007--0.00081 1E+10-1E+14 ohm 136 sec 600 V THERMAL PROPERTIES 13.9-103 in/in-F 0.478 BTU/lb-F 0.694-0.902 BTU-in/hr-ft-F 266-334F 111-298F 55.4-460F 98.6-298F 95-298F 149F 149F 149F HB OPTICAL PROPERTIES 11% PROCESSING PROPERTIES 396-486F 428F 428F 428F 428F 95-120F 180F ABS MOLDED PHYSICAL PROPERTIES

Density Water Absorption Moisture Absorption at Equilibrium Water Absorption at Saturation Linear Mold Shrinkage Melt Flow Hardness, Rockwell R Hardness, Shore D Tensile Strength, Ultimate Tensile Strength, Yield Elongation @ break Elongation @ Yield

0.0368-0.0437 lb/in3 0.05-1.8 % 0.35-0.45 % 0.30% 0.0024-0.0165 in/in 0.5-45 g/10 min MECHANICAL PROPERTIES 88-118 100 4320-9430 psi 4290-9430 psi 2-110 % 1.7-6 %

Tensile Modulus Flexural Modulus Flexural Yield Strength Compressive Yield Strength Izod Impact, Notched Izod Impact, Unnotched Izod Impact, Notched Low Temp Charpy Impact, Unnotched Charpy Impact, Notched Low Temp Charpy Impact, Unnotched Low Temp Charpy Impact Gardner Impact Tensile Creep Modulus, 1 hour Tensile Creep Modulus, 1000 hours Electrical Resistivity Dielectric Constant Dielectric Constant, Low Frequency Dielectric Strength Dissipation Factor Dissipatin Factor, Low Frequency Surface Resistance Arc Resistance Comparative Tracking Index Hot Wire Ignition, HWI High Amp Arc Ignition, HAI High Voltage Arc-Tracking Rate, HVTR CTE, linear 200 C Heat Capacity Thermal Conductivity Maximum Service Temperature, Air Deflection Temperature at 0.46 MPa Deflection Temperature at 1.8 MPa Vicat Softening Point Glass Temperature UL RTI, Electrical UL RTI, Mechanical with Impact UL RTI, Mechanical without Impact Flammability, UL94 Oxygen Index Gloss Processing Temperature Rear Barrel Temperature Middle Barrel Temperatue Front Barrel Temperature Nozzle Temperature Mold Temperature Drying Temperature

260-464 ksi 233-856 ksi 6930-15500 psi 7690-12500 psi 0.749-12 ft-lb/in 20-NB 0.899-4.01 ft-lb/in 23.8-114 ft-lb/in2 0.952-7.61 ft-lb/in2 1.43-NB 2.38-33.3 ft-lb/in2 1.33-14.6 ft-lb 290000-363000 psi 167000-276000 psi ELECTRICAL PROPERTIES 1E+14-1E+16 ohm-cm 2.7-3.2 2.7-3.5 399-864 kV/in 0.005-0.019 0.005--0.016 1E+13-1E+15 ohm 60-120 sec 400-600 V 7-15 sec 15-120 arcs 0.394-11.8 in/min THERMAL PROPERTIES 36.1-83.3 in/in-F 0.468-0.509 BTU/lb-F 0.888-1.32 BTU-in/hr-ft-F 140-223F 154-284F 165-428F 189-284F 225-239F 140-176F 140-176F 140-176F HB 19% OPTICAL PROPERTIES 40-96 % PROCESSING PROPERTIES 399-500F 482F 482F 482F 482F 109-149F 171-205F