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Engineering Polymers

Blow Moulding of Technical Components

Table of Contents PageWhy Blow Moulding ............... 2

DuPont’s offering .................... 2

Polyester resins ........................ 2

Nylon resins ............................. 2

Under-bonnet components ....... 2

PageAir duct system ........................ 3

Cooling circuit system 3

CVJ-boots and bellows ............ 3

Fuel tanks ................................. 4

Blow moulding technologies ... 4

Applications ............................. 8 to 15

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2

Why Blow Moulding

• Cost and weight reduction• Recyclability (i.e. replaces rubber)• Innovation:

– Multifunctional parts– Reduce number of parts in the engine compartment

• Higher temperature under the bonnet• Easier assembly and disassembly• Reduce number of materials• Improve engine performance up to 2%

(air intake manifolds; air ducts)• Reduce noise

DuPont’s offering in Blow Moulding• Resin HYTREL* TPE

CRASTIN* PBTZYTEL* BM PAZYTEL 330 Amorphous nylonSELAR* RB Barrier resin

• Design support• CAD support• Processing support

Polyester resins for Blow Moulding

Resins Hardness (shore D)HYTREL HTR 8105 47DHYTREL HTR 5612 50DHYTREL HTR 4275 55DHYTREL ETP 1383 62DHYTREL with higher melt strength(under development)CRASTIN XMB6400 Rockwell (M) 75CRASTIN with higher melt strength(under development)

HYTREL and CRASTIN PBT are compatible forsequential and multi-layer co-extrusion. They canprovide hard and soft segment combinations aswell as multi-layer structures.

Typical applications: Air ducts, CVJ boots and bellows.

* DuPont’s registered trademark

Nylon resins for Blow MouldingZYTEL BM 7300T HSL

Unreinforced, toughened PA 6

ZYTEL BM 73G25T HSL25% glass reinforced, toughened PA 6

ZYTEL BM 7300 FNUnreinforced, PA 6 flexible nylon alloy

ZYTEL BM PA 66 based blow mouldable nylons are currently under development:– unreinforced, toughened– glass reinforced, toughened– hydrolysis resistant.

ZYTEL 330Transparent, amorphous nylon

SELAR RBNylon barrier resin (for use with polyolefins)

PA 6 and flexible nylon based resins are compa-tible for sequential and multilayer co-extrusion, toprovide hard and soft segment combinations andmulti-layer structures.Typical applications: Cooling circuit parts, airducts, resonators, etc.

Blow moulded under-bonnet components

Current and potential use for blow mouldedDuPont engineering plastics include:• Turbo charge ducts• Air ducts – Clean air – Recycled air• Crankcase venting hoses• Oil cooling pipes and hoses• Resonators• Coolant system pipes and hoses• Coolant reservoirs• Air conditioning pipes and hoses

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Air duct system

1) Clean air2) Crankcase housing venting hose3) Recycled air4) Recycled charged airA) Air filterB) ChargerC) Heat exchanger for charged air

Requirements for air ductsTemperature range120 – 140 °C petrol engines140 – 160 °C diesel engines

Pressure range1,2 – 2 bar charge pressure

Chemical resistanceOil, blow-by gas and petrol

Typical fatigue testStress cycles 1000 000Pulsating pressure range 1,2 – 2 barTest medium airTemperature 132 ± 2 °CAmbient air temperature 85 ± 5 °CTest frequency 0,5 – 1 Hz

Suitable polymersTPE, PBT and nylon depending on individual application.

Cooling circuit system

A) Coolant radiator 1) Water cooling pipes and hosesA1) Header tanks in ZYTEL 2) Oil circuit pipes and hosesB) Oil cooler 3) Car interior heating hosesC) Air duct 4) Air conditioner pipes and hosesD) Heat exchanger for car interiorE) Air conditioner

Requirements for cooling circuitTemperature 130 – 140 °C continuousPressure 2 – 4 barChemical resistance 50/50 glycol water mixture

Suitable polymersPolyamides 6 or 66, unfilled and glass reinforceddepending on the application.

CVJ-boots and bellows

Benefits of HYTREL:• Greater toughness (5 – 10 times vs. rubber)• Longer life cycle• Better dimensional stability• No ballooning at high speed• Superior low temperature flexibility• Higher wear resistance• Lower permeation of oil and grease• Weight reduction against rubber

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2 A

B

C

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D

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2

B

C

1

A

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A1

A1

Fuel tanks with SELAR* RB

The DuPont patented “laminar barrier technology”uses SELAR RB to blow mould plastic fuel tankswith an integral laminar barrier :• 5 – 7% SELAR RB is added to HDPE• Up to 98% reduction of hydrocarbon emissions• Standard blow moulding equipment can be used• Industry and government regulations can be met.

Petrol tank requirementsEurope:• Effective Jan.’93 all EC countries must meet

evaporative emission limits of 2 g/2 h/vehicle.• Switzerland, Austria, Sweden require SHED**

test condition.• Test petrol contains no alcohols.• Commercial petrol may contain up to 3%

methanol, 5% ethanol, 15% ethers, with weightlimit of 2,8% oxygen.

Current requirements in USA:• SHED test 2 g/2 h/vehicle.Proposed CARB** shed test 2 g/25 h/vehicle forbuild schedule(by model year) : 10% 1995;30% 1996; 50% 1997; 100% 1998.• More States to follow with EPA** approval• EPA requires that a new car fulfills the require-

ment after 10 years or 100 000 miles • OEM's new objectives for petrol tank perme-

ation is up to 0,1 g/25 h (50% isooctane and50% toluene) Ref.-C test petrol.

• EPA will use EEE petrol without alcohols for thenew shed test.

• Testing with methanol fuel blends is onlyrequired for alternative fuel vehicles.

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Blow moulding technologies• Continuous extrusion blow moulding• Accumulator head blow moulding• Injection blow moulding• Multi-layer co-extrusion• Sequential co-extrusion

(hard/soft combination)• 3-dimensional blow moulding

– 3D Mono layer extrusion– 3D Multi-layer co-extrusion– 3D Sequential co-extrusion

Continuous extrusionThe parison is extruded continuously by constantlyrotating the screw of the plasticising unit.The process is very simple but requires the use ofhigh melt strength polymers to be able to makelong parts. A limitation is often the weight of theparison, as it has a tendency to elongate or collapseunder its own weight while being extruded rela-tively slowly out of the die. Continuous extrusionmachines are generally lower cost vs. other types.

* DuPont’s registered trademark

** SHED = Sealed Hose Emission Determination testCARB = Carlifornia Air Resource BureauEPA = Environmental Protection Agency

Multi-layer extrusionEquipment is available for continuous extrusion orwith accumulator head. Of importance is that sev-eral polymers can be extruded into a multi-layerparison. The thicknesses of the individual layersand the combination of polymers can be varied.The benefit is a structure which only uses the mini-mum amount of each individual polymer toachieve the required properties at the minimumcost.

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Accumulator headIn this process, the screw of the plasticising unit isrotating continuously and accumulates the moltenpolymer into a cylinder. The melt is then pushedout through the die by a piston in a very short time.This system has one advantage: it allows the use oflower melt strength resins as the parison does nothave to hang so long (typically one fifth of the timecompared to the continuous process) before beingmoulded. The machines are however more expen-sive but it is normally offset by more flexibility.

Injection blow mouldingIn this technology, the first step is the injectionmoulding of a preform. In some types of machinesthis preform is then blown up in a second stage. Inother types of machines, part of the preform (pari-son) is injected and the rest of the process is likethe accumulator head system (“Press blower”).

4-stage injection blowmoulding machine:

1) Injection mould2) Blow mould3) Stripping4) Core pin temperature

conditioning

3-stage injection blowmoulding machine:

1) Injection mould2) Blow mould3) Stripping

3-layer coextrusion1) Main extruder : Inner layer2) Satellite extruder 1 : Middle layer (e.g. recycled material)3) Sattelite extruder 2: Outer layer (e.g. high heat, abrasion

resistant, styling or barrier)

Sequential blow moulding

Material combination

Product line Hard Soft

Polyesters CRASTIN* HYTREL/ETP

Nylons ZYTEL BM ZYTEL BM 7300 FN

SequentialSequential blow moulding isalso beginning to make animpact in the air intake ductingsector. The process is a devel-opment of co-extrusion butrather than extruding an innerand outer layer together itinvolves, as the name suggests,extruding two different butcompatible plastic materials insequence. Most often, the resultis to combine hard and soft sec-tions in a single moulding. Extrusion head schematic

Typical sequential mouldedpart featuring a flexible sec-tion.

Sequential and multi-layer test• Trials where done at a blow moulding machinemanufacturer in Bonn, Germany, on a KruppKautex Co-Ex machine. The mould is a bellow testmould from Krupp Kautex.

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Hard Soft Hard

Two layer trial inner HYTREL 5612for good flex performance outerlayer is HYTRTEL ETP 1383 forhigh heat resistance

Left Centre Rightend bellow end

HARD SOFT HARD

CRASTIN HYTREL CRASTIN

XMB6400 ETP1383 XMB6400

CRASTIN HYTREL HTR CRASTIN

XMB6400 4275 BK XMB6400

ZYTEL BM ZYTEL BM ZYTEL BM7300T HSL 7300 FN 7300T HSL

ZYTEL BM ZYTEL BM ZYTEL BM7300T HSL 7300 FN 7300T HSL

3-dimensional blow mouldingIn addition to the above processes, 3-dimensionalblow moulding adds the possibility to make com-plex 3-dimensional parts. In all the conventionalprocesses, the limitation is the basic straight tube

shape of the parison from which any part has to bemade. With the various 3-dimensional systems (15 patented processes world wide), the parison canbe laid or manipulated in a 3-dimensional shape.

Movable Die Mould Movable Die Head

X

Y

ZX

Y

Z

The mouldstarts moving

Startingpoint

The mould finishes moving

3-dimensional blow moulding and 3-dimensional sequential Co-Ex

1) Flexibility of design

• Curved and complicated plastic pipes can bemade with ease in a single process with differenttypes of resins.• Different types of resins (hard type and softtype) can be located freely and easily with goodadhesion anywhere along the part.

2) Variety of resins

• Example of resin combination

Product line Hard Soft

Polyesters CRASTIN HYTREL/ETPXMB6400

Nylons ZYTEL BM ZYTEL BM7300T HSL 7300 FNZYTEL BM

73G25T HSL

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3) Basic structure of exchange blow moulding

4) Comparison

AssemblyParts operations

Pipe 2 0

Rubber hose 3 6

Hose band 6 6

Washer 6 6

Bolt 6 6

Total 23 pieces 24 operations

Traditional air flow pipe

Sequential co-extrusion air flow pipe

AssemblyParts operations

Pipe 1 2

Rubber hose 0 0

Hose band 2 2

Washer 2 2

Bolt 2 2

Total 7 pieces 8 operations

Commercial Application

Application: Air duct/high pressure/charged

Moulder : Helphos

OEM: Audi

Grade: HYTREL HTR 4275 BK

Status: Commercial

Comment: Metal inserts VW test temperature 150 °CIntegrated attachmentsHot plate welded side stud


Application: Air duct

Moulder : Kaiser

OEM: Audi


Status: Commercial

Comment: Achieved noise reductionWith integrated seal



Moulder : Helphos

OEM: VW - Corrado


Status: Commercial

Comment: Air duct with welded-on attachment andmetal inserts


Application: Bellow “La Bonette”

Moulder : Véhicules Industriels

OEM: Renault

Grade: ALCRYN 2070 BK

Status: Commercial

Comment: ALCRYN 2070 BK was chosen because of itsgood processing and weathering character-istics

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Application: Venting hose of crank shaft housing

Moulder : Helphos

OEM: VW - Golf A3


Status: Commercial

Comment: Metal inserts Flanges calibrated in the blow moulding process


Application: Air cooling duct (1 and 2)

Moulder : Helphos

OEM: VW


Status: Commercial

Comment: Duct 1 and 2 are snap-fitted with a blowmoulded snap-fit


Application: Venting hose of crank shaft housing

Moulder : Helphos

OEM: VW - Golf A3


Status: Commercial

Comment: Metal inserts, integrated shoulder for theattachment clip



Moulder : Kaiser

OEM: Audi


Status: Commercial

Comment: Air duct with integrated moulded-in seals



Moulder : Helphos

OEM: VW


Status: Commercial

Comment: Attachment integrated



Moulder : Helphos

OEM: VW


Status: Commercial

Comment: Moulded on attachment



Moulder : Helphos

OEM: VW - Golf A3


Status: Commercial

Comment: Metal inserts moulded on attachment



Moulder : Kaiser

OEM: Audi


Status: Commercial

Comment: Replaced ECO and saved about 40% of thecomponent cost due to integrated seals andeasier assembly

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Moulder : Helphos

OEM: VW


Status: Commercial

Comment: Integrated attachment and welded onattachment



Moulder : Kayser

OEM: Audi


Status: Commercial

Comment: This duct replaced ECO and saved about40% of the component cost due to easierassembly and integrated seals



Moulder : Helphos

OEM: VW


Status: Commercial

Comment: Metal inserts Moulded on attachment

Test Application

Application: Test mould steering bellow

Moulder : Krupp Kautex Machine Manufacturer

OEM:

Grade: HYTREL HTR 5612 BK/HYTREL ETP 1383

Status: Test

Comment: Co-ex Inside HYTREL HTR 5612 BK for optimal flexibility

Outside HYTREL ETP 1383 for high heat resistance


Application: VW Air ducts

Moulder : Helphos

OEM: VW


Status: Commercial

Comment: Several different air ducts



Moulder : Helphos

OEM: VW


Status: Commercial

Comment: Integrated attachment


Left : HYTREL; Right : ECO (epichlorhydrin rubber)


Moulder : Kaiser

OEM: Audi


Status: Commercial

Comment: Replaced ECO

Test Application

Application: Test mould


OEM:

Grade: ZYTEL BM

Status: Test

Comment: Sequential Co-extrusion

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Moulder : Kautex UK

OEM: Ford - Zeta engine

Grade: ZYTEL BM

Status: Commercial

Comment: Ford prefers ZYTEL for higher temperaturerequirement



Moulder : Phoenix

OEM: VW


Status: Commercial

Comment: The crank case vent goes in the studs’ inte-grated in the part that is why oil resistanceat elevated temperature (150 °C) is required


Application: Resonator

Moulder : Kautex UK

OEM: Ford - Mondeo

Grade: ZYTEL BM

Status: Commercial

Comment: Ford prefers ZYTEL for high temperaturerequirements

Test Application

Application: Test mould


OEM:

Grade: CRASTIN XMB 6400 NC/HYTREL ETP 1383 NC

Status: Test

Comment: Sequential Coexhard ends with CRASTIN XMB 6400soft bellow made of HYTREL ETP 1383



Moulder : Kayser

OEM: Audi


Status: Commercial

Comment: With integrated moulded-in seals


Application: Shock absorber sleeve

Moulder : Contitech (Dannenberg)

OEM: Mercedes

Grade: ZYTEL BM

Status: Commercial

Comment: This part had to be in PA 66 to meet HDTrequirements. ZYTEL CFE 8005 BK was theonly blow moulding nylon 66 resin avail-able to fulfill requirements


Application: Crank case venting hose

Moulder : Kayser

OEM: Audi


Status: Commercial

Comment: Replaced ECO for easier assembly andlower component cost.


Application: CVJ Boot

Moulder : Contitech

OEM: PSA


Status: Commercial

Comment: In use on the wheel sides. HYTREL was cho-sen because of its excellent low temperatureflexibility.

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Moulder : Contitech

OEM: Ford - Mondeo


Status: Commercial

Comment: Bellows made from HYTREL are used onwheel and engine side, 4 bellows are usedon each vehicle



Moulder : Contitech/Möller Werke/Paguag

OEM: VW (Golf)


Status: Commercial

Comment: VW choose HYTREL because of excellentlow temperature flexibility (no service fail-ure at –50 °C).

Development Application

Application: Lorry cable duct to the cabine.

Moulder :

OEM: DAF


Status: Development was not commercialised

Comment:


Application: Cooling pipe

Moulder :

OEM: BMW

Grade: PA 66, 30% glass reinforced

Status: Commercial

Comment:

BeneluxDu Pont de Nemours (Belgium)Antoon Spinoystraat 6B-2800 MechelenTel. (15) 44 14 11Telex 22 554Telefax (15) 44 14 09

BulgariaDu Pont Bulgaria18, Tcherni Vrah Blvd.Bldg. 2, Floor 5BG-1407 SofiaTel. (2) 66 59 13/66 57 36Telex 24 261 DUPONT BGTelefax (2) 65 63 29/66 56 11

CeskoslovenskoDu Pont - Conoco CS Spol. S.R.O.Palác Kultury5, Kvetna 65CS-14009 Praha 4Tel. (02) 422 641 to 422 646Telex 121 834 DUPO CTelefax (02) 499 209

DanmarkDu Pont DanmarkBranch of Du Pont Scandinavia ABParkallé 292DK-2605 BrøndbyTel. (43) 63 32 66Telex 33 263 DUPONT DKTelefax (43) 63 38 33

DeutschlandDu Pont de Nemours (Deutschland) GmbHDuPont Straße 1D-61343 Bad HomburgTel. (06172) 87 0Telex 410 676 DPD DTelefax (06172) 87 15 00

EgyptMedgenco International Trade Co.13, El Bostan StreetET-CairoTel. (02) 392 78 66Telex 93 742 MK UNTelefax (02) 392 84 87

EspañaDu Pont Ibérica S. A.Tuset, 23, 1°E-08006 BarcelonaTel. (3) 200 73 11Telex 50 887 DUPO ETelefax (3) 414 28 75

FranceDu Pont de Nemours (France) S.A.137, rue de l’UniversitéF-75334 Paris Cedex 07Tel. (1) 45 50 65 50Telex 206 772 duponTelefax (1) 47 53 09 67

HellasC. G. Lazarakis LtdValaoritou Street 17GR-10671 AthinaTel. (01) 361 84 11Telex 219 037 LACO GRTelefax (01) 362 09 30

IsraëlGadot Chemical Terminals (1985) Ltd.22, Shalom Aleichem StreetIL-633 43 Tel AvivTel. (3) 528 62 62Telex 33 744 GADOT ILTelefax (3) 282 717

ItaliaDu Pont de Nemours Italiana S. p. A.Via A. Volta, 16I-20093 Cologno Monzese MiTel. (02) 25 302 1Telex 314 671 DUPIT ITelefax (02) 27 300 969

MagyaroszágDu Pont - Conoco Hungary KFTTheokoely Ut. 137H-1145 BudapestTel. (1) 183 51 40Telex 202 805 DUPON HTelefax (1) 251 43 45

MarocDeborel Maroc S. A.Résidence Firdaous40, boulevard d’Anfa - 10°MA-CasablancaTel. (2) 27 48 75Telex 23 719 BOUKBENTelefax (2) 26 54 34

NorgeNordic Polymers A/SNiels Leuchsvei 99N-1343 EiksmarkaTel. 67 14 28 70 Telefax 67 14 30 44

ÖsterreichInterowaFürer-Haimendorf KGBräuhausgasse 3-5A-1050 WienTel. (01) 512 35 71Telex 112 993 IROWA ATelefax (01) 512 35 71 12/512 35 71 31

PolskaE. I. du Pont de Nemours & Co.Warsaw Branch OfficeIntraco Bldg - Floor 13ul. Stawki 2PL-00193 WarszawaTel. (2) 635 04 01Telex 812 376 DUP PLTelefax (2) 635 07 61

PortugalMario CoelhoRua do Campo Alegre, 672 - 1°P-4100 PortoTel. (2) 69 24 25/69 26 64Telex 23 136 MACOLTelefax (2) 600 02 07

RomaniaAectra International LtdDistributor for DuPontStrada Luterana 2 - 4Hotel Bucuresti Corp. D2,Etay 2, Ap. 6Of. Postal 45-13R-70741 BucurestiTel. 14 34 14Telex 92 512 DPX RTelefax 13 50 75

RussiaDu Pont RussiaYuzhinsky Pereulok 13/2SU-103 104 MoskvaTel. (095) 973 10 01Telex 413 778 DUMOS SUTelefax (095) 973 24 40

Schweiz/Suisse/SvizzeraDolder AGImmengasse 9Postfach 14695CH-4004 BaselTel. (061) 326 66 00Telex 962 306 DOL CHTelefax (061) 326 62 04

SlovenijaDu Pont de Nemours International S.A.Representative Office16, Tolstojeva Ulica61000 Ljubljana, SlovenijaTel. (061) 34 43 93Telex 31 108 BETI YUTelefax (061) 34 43 93

Suomi/FinlandSuomen Du Pont OyLapinlahdenkatu 3A 20 (Lappviksgat)PL 237SF-00181 HelsinkiTel. (90) 694 55 22Telefax (90) 694 53 11

SverigeDu Pont Scandinavia ABTorshamnsgatan 35S-164 86 Kista (Stockholm)Tel. (08) 750 37 00Telex 12 410 DUPONO STelefax (08) 750 90 41

TürkiyeGrillo Maden Ltd.Inonu Caddesi 96/6TR-80090 Taksim-IstanbulTel. (1) 149 83 10Telex 24 271 GILO TRTelefax (1) 144 51 13

United KingdomDu Pont (U.K.) LimitedMaylands AvenueGB-Hemel HempsteadHerts. HP2 7DPTel. (0442) 21 85 00Telex 825 713 DUPONT G Telefax (0442) 24 94 63

Asia PacificDu Pont Asia Pacific LtdPolymer ProductsP.O. Box TST 988511122 New World Office Bldg - East WingSalisbury RoadKowloon, Hong KongTel. (852) 734 53 45Telex 46 296 DPTHK HXTelefax (852) 724 44 58

South AfricaDu Pont de Nemours International S.A.South African Branch Office1st Floor Howick GardensHowick Close, Waterfall ParkVorna Valley Ext. 21, MidrandBox 3332, Halfway HouseTel. (11) 315 38 80Telex 426 513 DUPNTTelefax (11) 315 42 57

USAE. I. du Pont de Nemours & Co.Wilmington, Delaware 19898Tel. (302) 774 1000.Telex 67 17 325 DUPONT

Requests for further information from countries not listed aboveshould be sent to:

Du Pont de NemoursInternational S.A.2, chemin du PavillonCH-1218 Le Grand-Saconnex, GenevaTel. (022) 717 51 11Telex 415 777 DUP CHTelefax (022) 717 52 00

01.94 Printed in SwitzerlandH-53702

For further information contact:

This information corresponds to our current knowledge on the subject. It is offered solely to pro-vide possible suggestions for your own experimentations. It is not intended, however, to substi-tute for any testing you may need to conduct to determine for yourself the suitability of our prod-ucts for your particular purposes. This information may be subject to revision as new knowledgeand experience becomes available. Since we cannot anticipate all variations in actual end-useconditions, DuPont makes no warranties and assumes no liability in connection with any use ofthis information. Nothing in this publication is to be considered as a license to operate under or arecommendation to infringe any patent right.

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