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Engineering Design2009-01

High performance DuPont materials can contribute to weight reduction, fuel savingsand CO2 emission reductions.

Read more on pages 2 - 3

The quest for sustainable mobility

In dealing with one of the greatest chal-lenges facing the automotive industry,we are working with many of our cus-tomers to achieve more sustainablemobility in response to high fuel costs,regulatory requirements and the needto reduce CO2 emissions. Among theoptions currently being explored areways of improving vehicle efficiency byreducing energy loss through friction,the reduction of overall vehicle weightthrough advanced metal replacement,and the use of new technologies toboost the output of smaller engines. At the same time, automotive manufac-turers are introducing more advancedpropulsion systems – from hybridsthrough fuel cells – that can run on vari-ous alternative energy sources.

Contributing to energy savings todayThis tremendous challenge has causedus to rethink a number of componentsand systems, especially in the engine,driveline and fuel systems. The stakesfor reducing a vehicle’s carbon foot-print and improving fuel economy arehigh. Several studies show a 25 kg(55 lb) weight reduction can yield a 1%increase in fuel economy, dependingon the vehicle. A 100 kg (220 lb)weight reduction can reduce CO2 emis-sions by 8.5 g per km (approximately0.5 oz per mile). High performanceDuPont engineering resins make thereplacement of metal parts and compo-

nents possible, contributing to weightreduction, fuel savings and CO2 emis-sion reductions. DuPont™ Zytel®

nylon resin, for instance, has long beenadopted for GM’s 3800 series V6engine manifold. By replacing metaland reducing weight, this change hassaved over 2.6 million barrels of oilfrom 1992-2006.

In a life cycle analysis of the use ofvirgin glass-reinforced nylon, in placeof secondary aluminum, for an enginecomponent of the Ford F250 truck, itwas found that the benefits attributa-ble to the reduced vehicle weight faroffset energy consumption duringmanufacture. During the ten year life-time of 100,000 trucks included in theanalysis, a 77 billion BTU (British Ther-mal Unit) net energy saving wasachieved and 5,000 t (11 million lb) ofCO2 emissions were eliminated. Theenergy savings could create enoughelectricity to meet the needs of fivethousand homes for an entire year. Inaddition, DuPont™ Zytel® nylon resinhas contributed to weight savings in anumber of system components. As anexample, described in further detail inthis issue of Engineering Design, theuse of Zytel® as an alternative to alu-minum for the lower section of an oilpan module from Daimler, helped cutthe weight of that component by nearly50% (see also insert on SPE innovationaward).

The stakes for reducing energy lossthrough friction are also high. Studieshave shown that approximately 15% ofthe energy available in gasoline actuallygets used to move a vehicle down theroad. The remaining 85% of the energy islost to engine and driveline inefficien-cies, accessories and idling. To help theautomotive industry improve efficiencyand get more power to the wheel, DuPonthas created the 'Science of Friction' pro-gram to put the science of DuPont materi-als – from DuPont™ Vespel® parts andshapes to DuPont™ Teflon® – to workand reduce friction, especially in drive-line systems. For example, Vespel®

demonstrates a 30% to 40% reduction infriction when used in fork pads, whichare used to engage gear sets in manualtransmissions. Similarly, the use ofVespel® in automatic transmissions can

2 Engineering Design 2009-01

The quest for sustainable mobility By Patrick Ferronato, global automotive marketing director at DuPont Engineering Polymers

Patrick Ferronato

According to Toyota, the V-6 powered 2006 LexusGS-300 is approximately one percentmore fuel efficient – the equivalent ofapproximately 23 l (6 gallons) of gaso-line per vehicle per year* – thanks tothe plastic water jacket spacer, madefrom DuPont™ Zytel® HTN PPA (*basedon the US EPA Fuel Economy website,assuming a vehicle is driven an averageof 15,000 miles per year)

Significant breakthroughs in sustainability honored

Two breakthroughs in automotive sustainability, featuring high performance polymers fromDuPont, were recently honored by The Society of Plastics Engineers (SPE) Automotive Divi-sion. An oil pan for Daimler’s new 4-cylinder diesel engine (OM651), the first worldwide toconsist of a polymer module (made of DuPont™ Zytel® nylon – see pages 4&5), took top hon-ors in the powertrain/chassis category (Daimler representatives Dr. Günther B. Zoll (left), spe-cialist supervisor plastic engine components, and Nuri Tiraki, project development engineerfor the OM651, are pictured with the module and award). Meanwhile Ford was named finalist in the powertrain/chassis cate-gory for an innovative 'capless' fuel filler system which uses DuPont™ Zytel® HTN PPA. The new system is compatible withbiofuels and supports the compliance of Ford’s vehicles to all California Low Emission Vehicle (LEV II or PZEV) requirements.

First polymer oil pan module for use in serial-production carsA joint development between Daimler, Bruss and

DuPont saves manufacturing cost as well as weight.

Page 6New wheel safety technologyVisiLok, a patented system featuring a housing

made of robust Zytel® HTN, provides an effective

solution to the risk of wheel detachment

Page 7Extending new processing technologiesMaterial and technical support from DuPont has

enabled Turkish automotive supplier Teklas to pro-

duce 3D blow-molded parts.

Page 8 A new track for Zytel®

A new railway fastening system is one of the first to

use a base plate made of Zytel® nylon as an alterna-

tive to steel.

Page 10Meeting a 'baffling' design challengeAn integrated baffle and seal lip assembly, made

of Hytrel®, is used in two new transmissions from

General Motors.

Pages 11 & 12News New Delrin® 300CP for enhanced cost-effi-

ciency; Crastin® and DuPont dye-sublimation tech-

nology used for limited-edition champagne bottles;

DuPont extends its MetaFuse™ alliance.

Page 13Promoting safer oven useThe ‘Impulse’ guide for Fagor ovens, mounted on a

support made of Zenite® and metal, enables safe

and easy access to cooked food.

Page 14Smooth operatorPatented ball transfer units, made using DuPont™

Vespel® parts and shapes, are used for the smooth and

efficient handling of flat panel displays and solar panels.

Engineering Design 2009-01 3

This issue in brief

improve the torque loss of seal rings byup to 50%. Additionally, automotivemanufacturers can increase loads onthrust washers twofold, encouraging fur-ther metal replacement for weight andspace savings.

Energy savings for the futureLooking to the future, and with a newgeneration of propulsion systems inmind, DuPont is also leading the devel-opment of safer, more efficient energystorage options for a variety of con-sumer and industrial applications,including electric/hybrid vehicles. Ourfocus is on creating energy storageoptions that result in less wastedenergy and heat gain due to low resist-ance, longer device life from less heatand higher performance materials(chemical and thermal stability), higher

energy output due to a thinner separa-tor (resulting in more active materialsin the same space) and processing costsavings, due to higher temperature sta-bility and less water absorption.

Key DuPont products in develop-ment for the energy storage sectorinclude: DuPont Hybrid MembraneTechnology for battery separators; engi-neering polymers such as Zytel® nylonfor battery pack housings, sealants andconnectors; fluoropolymer resins forcapacitors and lithium ion batteries;and DuPont Teijin Films separators fordry capacitors. For instance, DuPont isdeveloping a battery separator for elec-tric/hybrid vehicles which will enablehigher operating temperatures in use,more power generation and lower ionicresistance for increased battery output.

In device testing to date, DuPont

has seen up to a 40% improvement inthe life of the device with properlydesigned energy storage components,such as super-capacitors. Our HybridMembrane Technology has shown sig-nificant advantages in high power appli-cations — in devices it will deliver up to50% more energy at high dischargerates. Meanwhile, our higher tempera-ture materials have enabled the reduc-tion of production times and broadeneddevice application temperature capabil-ities. The results of this smarter engi-neering? The potential for increasedpower density and less wasted energyand heat gain; increased energy supplyand the enabling of smaller devices;higher process temperatures, resultingin reduced manufacturing costs andimproved device life and effective barri-ers to address safety issues.


To date, thermoplastics have success-fully replaced metal in applications suchas air intake manifolds, slide and ten-sioning rails, cylinder head covers and,most recently, oil filter modules. Now,with the first oil pan module to be madeof a thermoplastic polymer for serial-production cars, Daimler has brokennew ground. Since the end of 2008, it ispart of the new 4 cylinder diesel engine(model OM651), used initially in carsbelonging to the C Class range. Variousadditional ranges are set to follow.

A complex set of requirements Vehicle oil pans are exposed to a com-bination of stresses as a result of lubri-cant-use, temperature changes andstatic and dynamic loads. Even so, theirseal performance must be maintainedin all conditions. Additionally, the panis required to withstand the rough hand ling by a forklift truck of the com-bined engine and gearbox unit.

Its specifications are correspond-ingly diverse and complex. It was forthis reason that the development team

decided from the outset to useDuPont™ Zytel® 70G35 HSLR A4, aglass-fiber reinforced, heat-stabilizedand hydrolysis-resistant grade of nylon66, which is tried and trusted forengine components. Its high melt flowenables long flow distances, shortinjection times and the molding of thinpartition walls and ribbing.

Integrated oil deflector asreinforcement Fundamental to the design of the oilpan was the need to achieve sufficientstiffness within the flat section ahead

Zytel® 70G35 HSLR A4

� High flow � Easy to weld� Stiff and dimensionally stable� Hydrolysis-, temperature- and

chemical resistant

Oil pans for cars were one of the last great strongholds

of metal. Now, for the first time, an oil pan module

made of polymer has gone into serial production. The

joint development, between Daimler, the supplier Bruss

and DuPont, saves manufacturing cost as well as

weight, and – in the long term – offers the potential for

greater functional integration.

First polymer oil pan module for use inserial-production cars By Dirk Winnemann, DuPont Engineering Polymers, Germany


of the oil sump, thereby minimizingsealing area deformation. The adop-tion of any internal ribbing should notinterrupt oil flow, while the use ofexternal, reinforcement ribbing wasalmost impossible due to the lack ofavailable space.

The solution was to create a sand-wich design with two injection-moldedparts. A separately-produced oil deflec-tor is welded onto the flat section of thepan, and is used to calm the oil churnedby the crankshaft and balance shaft,and direct it back into the oil pan.

Moreover, the deflector signifi-cantly improves the vibration behaviorof the overall design. The high rein-forcement ribbing in the sump simulta-neously acts as a baffle, also helping tocalm the oil. A die-cast aluminum uppershell is used to attach the oil pan to theengine block. The overall constructionachieves a significant weight reductionof 1.1 kg compared to an entirely alu-minum design.

Simulation shortens development time Before producing the first tool, Brussrequested technical support fromDuPont in addition to its own, compre-

hensive simulation software. Finite ele-ment analysis (FEA) was used to refinethe positioning of the ribbing at theedge of the pan, thereby contributingsignificantly to the overall stiffness ofthe critical flat section despite its mini-mal height. Flow studies, also based onFEA modeling, were used by DuPont togauge and optimize the impact of wallthickness, the number of gates, andtheir positioning, on weld line forma-tion and warpage behavior. Indeed,due to the high melt flow of Zytel®

70G35 HSLR A4, a single, central gatewas enough to completely fill themould cavity, while permitting shortmolding cycles.

Finally, at the DuPont EuropeanTechnical Centre in Geneva, the struc-ture’s properties were further analyzedby simulating the combined engine andgearbox unit being dropped heavily bya fork-lift truck. This allowed criticalparts – particularly the external ribbingdesignated for the contact area – to beidentified and dealt with. Real-life test-ing of prototype parts at Bruss con-firmed the success of the simulateddesign – even after 1000 hours of agingin hot oil at 150 °C (302 °F).

Welding of the oil deflector to theoil pan module was optimized by ateam comprising Bruss, DuPont and thejoining product manufacturer, Branson.All tolerances were defined with regardto process control and the materialused, in order to ensure reliable joints,even in unfavorable conditions. Subse-quent pull-off tests revealed pull-offforces of around 1300 N, a higher valuethan required.

In its current form, the componentmeets all requirements. The seal arearemains leak free during hot oil testingat 150 °C, at minimum sealing force(smallest seal in largest groove) andduring alternating climate testing.

Wide scope for integrationIncreased integration means lowermanufacturing costs. In its currentform, and as described in this article,an oil deflector has already been inte-grated. Additional functions, envisagedfor integration in future oil pan models,could include the oil pick-up pipe, oillevel switch, oil filter and other oilreturn components or oil pumps.

Contact

Daimler AG, Mercedes-Benz Cars70546 Stuttgart, GermanyDr. Günther B. ZollTel. +49 711 17 20 235Fax +49 711 17 790 20 [email protected]

Dichtungstechnik G.BRUSS GmbH & Co KG22955 Hoisdorf, GermanyDr.-Ing. Roland KralTel. +49 4107 59 386Fax +49 4107 378 72 [email protected]

The C-Class from Mer-cedes-Benz has rear-wheel drive and theengine is installedlengthwise. As a result,the oil pan is partiallysituated above thecross beam of the frontaxle. This requires thissection to be kept veryflat. The part behind it– in terms of directionof travel – forms theconsiderably deeperoil sump, with a capac-ity for approximately 6liters of motor oil.

Simulations of structure-borne noise,carried out by DuPont, were carried out

with partially-filled oil pans

New wheel safetytechnologyBy Rob Coates, DuPont Engineering Polymers, UK

Wheel nut relaxation is a serious andrecognized global issue in the commer-cial transport industry. The typicalannual frequency in the UK of wheel fix-ing defects is between 7,500 and11,000, resulting in between 150 and400 wheel detachments. Although theexact cause of wheel nut relaxation andlosses is not yet known, it is clear thatif not managed correctly, operators andmanagement teams around the worldcould face severe penalties and evenprosecution.

The VisiLok road wheel safety nut isthe culmination of four years ofresearch and development, testing andtrials, which addresses both the needfor nut retention and relaxation indica-tion. It consists of a steel nut incorpo-rating a spring-driven lock and flagmechanism (housed in a 50% glass-

reinforced grade of Zytel® HTN) and amodified, slotted stud. In the event ofclamping force being lost, the nutstarts to rotate. At this point theVisiLok system arrests further rotationin order to prevent the nut spinning off.At the same time, highly visible, yellowflags are displayed to alert the operatorthat the wheel requires attention. Whileachieving the dual function of arrestingthe movement and flagging the prob-lem, VisiLok behaves in all otherrespects as a standard road wheel nut.No special tools are required and thereis no time loss in fitting or removing aVisiLok nut.

Reasons for the selection of theparticular grade of Zytel® HTN, 53G50,for the housing of the lock and flagmechanism were numerous. The poly-mer’s high stiffness prevents deforma-

tion of the housing dur-ing use, while itsdimensional stability is fundamen-tal to the long-term, reliable operationof the safety device. Moreover, despitebeing partially embedded within thesteel nut, the upper section of thehousing is exposed to road conditions,requiring the polymer to be resistant tochemicals such as road salts, oil andfuel, as well as forceful impacts.

“After going through a number ofdevelopment stages which includedproving the basic integrity of the designconcept and function, we needed toensure that the VisiLok nut and stud wasrobust in all operating conditions, inwhich respect the adoption of Zytel®

HTN for the housing of the safety mecha-nism was key,” explains BarryMcGowan, managing director of VisiLokLimited (pictured left with the VisiLoknut). “We selected the componentmaterial combinations carefully to pre-vent corrosion from jamming the mecha-nism, while keeping the componentcount to a minimum, and ultimately pro-duce a cost-effective, universally applica-ble solution which would put an end tothe wheel loss problem once and for all.”

Each year thousands of commercial transport and

heavy goods vehicle operators are faced with the risk

of sudden and often unexplained wheel fixing defects

or detachment. A patented system from the UK com-

pany VisiLok Limited, and featuring a housing made of

robust DuPont™ Zytel® HTN, provides an effective

solution which addresses nut relaxation the instant it

occurs and flags the operator into action.

Contact

VisiLok LimitedHenfaes LaneWelshpool, SY21 7BJ, UKTel +44 1938 553380 [email protected]

DuPont™ Zytel® HTN

� High stiffness and dimensionalstability

� Impact resistance� Chemical resistance



The majority of the 37-year historyof Teklas Kaucuk Sanayi ve Ticaret A.S(Gebze, Turkey) has been as a producerof rubber-based parts for the automo-tive industry. The broad range of prod-ucts produced at its Turkish and Bul-

garian facilities include turbo -charger hoses, cooling hoses, brakehoses, fuel lines, windshield wipers andanti-vibration parts. Yet, it was the real-ization of the value to be gained byTeklas and its customers from the pro-duction of blow-molded air ducts usingthermoplastics, that led to the companyturning to DuPont for the material anddevelopment support required to engagein the technically-challenging process ofthree-dimensional (3D) blow molding.

3D blow molding is an establishedapproach for demanding duct and fuel-system parts. The process allows layingextruded parisons into special moldsusing robotic manipulation and suction.These 3D techniques produce contouredparts that are virtually flash-free, with aminimum of pinch-off points or knitlines on the finished part, to improvemechanical performance in criticalstressed areas. DuPont has installed 3D

blow molding equipment at its EuropeanTechnical Center (ETC) in Geneva,Switzerland, for use with its modifiedengineering thermoplatics for advancedblow molding. Following the signing of adevelopment agreement between thetwo companies, technical representa-tives of Teklas visited the ETC in 2006.

Teklas took delivery of its first 3D blowmolding machine at the start of 2007, andimmediately set about the developmentof an intercooler air duct for Seat – a com-plex challenge, even for those with moreexperience of the processing technique.Indeed, Teklas was at first so unsure of itsability to produce the complex part usinga single tool, that its initial plan was tomold the duct in two parts and to subse-quently weld them together. However,with DuPont’s support, Teklas succeededin producing a single part made ofDuPont™ Zytel® BM73G15THS, a 15%glass-fiber reinforced, heat stabilized,lubricated and toughened polyamide 6for blow molding. Specific applicationrequirements for the material includedresistance to temperatures of around155 °C (355 °F) and 1.9 bar air pressure.The duct and the material have since

been approved by Seat.“Over the course of the last 18

months we have learnt a lot about 3Dblow molding, and currently have severalair duct projects in development withOEMs,” comments Murat Bozkurtlu, busi-ness development manager at Teklas.“Our success in this area is primarily dueto the partner-like approach of DuPont toextending our knowledge of this relativelynew processing technology, as well as the quality of its materials.”

Extending newprocessing technologiesBy Hasan Camur, DuPont Engineering Polymers,Turkey

Seeking to extend its pro-

cessing capabilities, the

Turkish automotive sup-

plier Teklas chose

DuPont as its develop-

ment partner for the

production of 3D

blow-molded parts

on the basis of its

high performance

DuPont™ Zytel®

nylon and first class

technical support.

Contact

Teklas Kaucuk Sanayi ve Ticaret A.SBaris Mah. Kosuyolu Cad. No: 94 41400 Gebze/Kocaeli, TurkeyTel. +90 (262) 648 44 00Fax +90 (262) 641 79 63www.teklas.com.tr

Cooperation between DuPont and Teklas resulted in the successful blow molding ofthe intercooler air duct for Seat: (left to right) Yavuz Tugyan (technical manager atDuPont Turkey), Murat Bozkurtlu (business development manager at Teklas), HasanCamur (sales & marketing manager, DuPont Turkey), Adem Senemtası (executivetechnician, Teklas) and Nedim Us (executive production leader, Teklas)

DuPont™ Zytel® nylon

� Blow-molding grade� Mechanical performance� Temperature resistance


A new track for Zytel®By Josep Ros and Jaume Ventayol, DuPont EngineeringPolymers, Spain

Railway fastenings fulfill a number offunctions. Beyond their obvious tasksof keeping the rail attached to thesleeper and maintaining the longitudi-nal direction, gauge and inclination ofthe rails, one of their principal roles isto spread, absorb and transmit thedynamic loads from the wheels of themoving train to the sleeper and trackbed. It was in relation to performancein this key area that Mondragón Solu-ciones, a Spanish company with morethan 50 years of experience in produc-ing injection-molded parts for telecom-munications and railroad industries,sought an alternative to the steel base

plates commonly used in railway fas-tenings around the world. “We wantedto replace steel with nylon in thisextremely critical application – whichtakes the full impact of the train wheel– in order to gain performance benefitsthat were previously unobtainable dueto the rigidity of steel,” explains JuanVives Clavel, director of R&D at Mon-dragón Soluciones. “We chose a 35%glass-fiber reinforced grade ofDuPont™ Zytel® as the replacementmaterial – a nylon resin we werealready familiar with in terms of its highdimensional stability and ease of pro-cessing.”

A range of benefitsInitial trials and prototype testing ofbase plates molded from Zytel®

70G35HSL demonstrated that the mate-rial possesses not only a high modulusof elasticity, required to withstand theimpact of train wheels, but also suffi-cient elongation at break. As a result,the nylon plate is capable of absorbingenergy generated by the passing train,thereby reducing the impact and vibra-tion forces responsible for track deteri-oration. The dielectric strength of thematerial, necessary to electrically-isolate the tracks from the ground andfrom each other, also far exceeded cus-

Mondragón Soluciones, of

Valencia, Spain, has been a

manufacturer of railway fas-

tenings for more than fifteen

years, with a reputation for inno-

vative products. None more so

than its latest fastening product,

which is one of the first to feature a

base plate made of DuPont™ Zytel®

nylon, chosen for its elasticity and

strength, as a lightweight and robust

alternative to steel.

Therailway

fastening systemfrom Mondragón

Soluciones is one of the first tofeature a black base plate made of

DuPont™ Zytel® nylon, secured by metaltension clamps (in green)

tomers’ require-ments. “To further ensure

that both the design and the mate-rial met all our customers’ expecta-tions, we conducted additional testswhich enabled us to confidently predictthat the base plate molded from Zytel®

would retain its mechanical propertiesin the long-term. This is due, in largepart, to the nylon’s high chemicalresistance to products such as oils,

greases and herbicides that are occa-sionally used during track mainte-nance,” adds Juan Vives Clavel.

Familiar with the injection-moldingof Zytel® from previous developments,the processing of the nylon baseplates presented few problems to thetechnicians at Mondragón Soluciones.Demolding was facilitated by the useof a small draft angle, despite thepart’s high wall thickness, while sinkmarks at the intersection of the rib-bing and the walls of the molded partwere avoided by optimizing the rib-bing’s thickness. “As with previousprojects, the support and advice thatDuPont provides has given us addi-tional confidence in our choice ofmaterial, and we value it highly,” addsJuan Vives Clavel.

Further confirmation of Zytel®

nylon resin as a suitable alternative tosteel for the application soon fol-lowed. The Mondragón Soluciones’design has since been certified as con-forming to the Spanish standard UNE-EN 13146 by the Laboratory of Science and Engineering Materialsdepartment at the University ofCantabria. Those handling material

on-site have also welcomed the newproduct, which is transportedmanually to each sleeper, as it isapproximately a sixth of theweight of its steel equivalent.

A perfect partner: Hytrel® rail padsSimilar to other suppliers of railwayfastenings from around the world (seeED 2006-1), Mondragón Solucionesuses rail pads made of DuPont™Hytrel® thermoplastic polyester elas-tomer in its own systems (colored lightgray in exploded view, left of page). Thepads complement the base platesmade of Zytel® in terms of their per-formance, providing the ideal combina-tion of flexibility and durability requiredto perform under high load over anextended period. The chemical resist-ance of Hytrel® was a further keyrequirement.

The new fastenings were firstinstalled on a suburban metro line inMexico City during the first half of2008, and most recently for a tram sys-tem in Blankenberge, Belgium. “Ourexperience to date has confirmed ourdecision to develop this new type ofpolymer product. It combines therequired strength for the applicationwith the right elasticity, which is essen-tial when seeking to reduce impact andvibrations in the track structure. In factI would go as far as to say that it hasdestroyed the myth that steel must beused for this type of rail fastening,”concludes Juan Vives Clavel.


DuPont™ Zytel® nylon

� Strength and elasticity� Dielectric strength� Chemical resistance

Contact

Mondragón SolucionesPol. Ind. El Mediterráneoc/ La Fila núm. 5 46550 Albuixech, Valencia, SpainTel. +34 961 415 400 www.mondragonsoluciones.com

Familiar withthe processing of

Zytel® from previous projects, Mondragón Soluciones

avoided sink marks at the intersectionof the ribbing and the walls by optimizing

the ribbing’s thickness

General Motors’ new 6T40 and 6T45transversely mounted 6-speed auto-matic transmissions deliver power to awide range of vehicles available glob-ally from GM, including the 2008Chevrolet Malibu, Daewoo Tosca andBuick LaCrosse for the Chinese market.Located in the torque transfer case ofeach of these transmissions is an inte-grated baffle and seal lip assembly,made of Hytrel®, which is designed toreduce oil aeration, provide a seal thatlimits fluid from flooding the chain,while ultimately enabling transmissionfluid fill for life. The one-piece, flexiblecomponent significantly reduces overallcost because it avoids the use of costlymulti-step production and assemblyprocesses, which were typically metalstampings or plastic carriers with a rub-ber bead.

The close cooperationbetween DuPont and GM on thisproject started a couple of years ago,when they sought to optimize the mate-rial and process for the design. In turn,this would allow GM to cost-effectivelyrealize the full benefits of the innova-tion. Indeed, the eventual selection ofHytrel® was key to the design’s suc-cess. Even though it’s not typicallyconsidered for transmission applica-tions, it proved to offer the right bal-ance of flexibility and stiffness despitetemperature extremes to fit the com-plex geometries of the transfer case,while resisting swell when exposed tooils, aliphatics and aromatic solvents.

Two years of development saw tool-ing iterations and material upgrades tooptimize performance for service tem-peratures that cycle between -40 °C

(-40 °F) to +140 °C (284 °F). The teamextensively used the Troy-based DuPontAutomotive Application DevelopmentCenter to test materials, variousprocesses and tools. Now in produc-tion, the part is manufactured by ChunilEngineering in Korea and CWB Group inChina.

“The success of this design on the6T40 program was followed quickly byapplication of this design on the 6T45program, which recently went into pro-duction,” said Jatin Desai, GeneralMotors Powertrain transmission struc-tural component global team leader.“This generation offers improved per-formance, yet still packages the 6-speed into the space of a 4-speed.”

An integrated

baffle and seal lip

assembly, made of

DuPont™ Hytrel®

thermoplastic

polyester elastomer, is

used in two new transmis-

sions from General Motors. he

unique solution helps condense packaging space

and enable better clutch and transmission durability.


Meeting a “baffling” design challengeBy Dino Tres,DuPont Automotive development programs manager Polymers, US


DuPont has announced a long-term alliance with California-based PowerMetal Technologies, Inc. to further develop andcommercialize MetaFuse™ nanocrystalline metal/polymerhybrid technology, with initial development programs tar-geted at electronic hand-held devices, sporting goods, fur-niture, power tools and appliances. A similar alliance, tobring this technology to the automotive market, was signedwith Morph Technologies a year ago.

Under the agreement, DuPont will provide proprietaryresin formulation and application development leadershipto global customers to bring this innovative technology tomarket. PowerMetal will apply its nanotechnology expert-ise to the manufacture of extremely lightweight compo-nents with the strength and stiffness of metal combinedwith the design flexibility and lightweight benefits ofDuPont Engineering Polymers high-performance thermo-plastics. Other terms and conditions were not disclosed.

MetaFuse™ nanometal/polymer hybrids can be used tomanufacture extremely lightweight components with thestrength and stiffness of metal combined with the designflexibility and lightweight benefits of high-performancethermoplastics. The technology employs a proprietaryprocess that precisely applies ultra high-strengthnanometal to components made of DuPont engineeringpolymers to create lightweight components in myriad, com-plex shapes with the stiffness of magnesium or aluminumand higher strength. http://plastics.dupont.com

MetaFuse™ nanometal/polymer hybrid technology hasbeen developed by DuPont Engineering Polymers, Morph Technologies Inc., Integran Technologies Inc. and PowerMetal™ Technologies

DuPont extends MetaFuse™ alliance

The champagne bottle for the Taittinger Brut Millésimé 2000 – Rauschen-berg Collection, is encased in a molded “shell” of DuPont™ Crastin® PBT,and decorated using DuPont dye-sublimation technology – selected forits ability to accurately reproduce delicate artwork on complex shapes.

Created in 1983, the Taittinger Collection combines the genius ofmodern artists and the art of champagne. The collection is a series of limited-edition champagne bottles encased in a shell specially created byan artist to pay tribute to this wine. The most recent of the eleven artiststo be featured in this series is the American painter Robert Rauschen-berg, well-known for his “Combine” works that integrate the aspects ofpainting and sculpture.

“The artwork created by Rauschenberg for our 11th edition makes useof a largely chromatic, but very subtle, palette of colors, with very lightand “faded-looking” tones of mauve, brown and yellow, together withlarge areas of dark grey and black,” explains Dominique Garreta, market-ing director at Taittinger. “Three-dimensional sublimation printing wasthe most effective way of reproducing these very delicate colors on such acomplex shape, thereby requiring a material for the shell that wouldresist the temperatures incurred during the sublimation process.” Thisruled out ABS, the polymer initially foreseen for the application and usedin previous ranges, while subsequent testing demonstrated Crastin® toprovide the best combination of temperature resistance, colour reproduc-tion and post-shrinkage. The dye sublimation technology was developedby DuPont in partnership with Pacific Colour, of Lons-le-Saunier, France.

http://www.taittinger.com/la-taittinger-collection.html

Pictureperfect


Designers have typically had to makecompromises when balancing mold-ability, mechanical performance andlow temperature toughness in acetalparts. New Delrin® 300CP now pro-vides an almost universal solution. Thematerial demonstrates consistentimpact performance over a broad tem-perature range. For example, itsnotched Charpy impact strength of10.5 kJ/m2 at room temperature, onlyfalls to 10 kJ/m2 at -30 °C (-22 °F),whereas other, specially impact-modi-fied copolymers experience substantialfalls in this value at such temperatures

(e.g. from 13 kJ/m2 to 8 kJ/m2 with ahigh impact-resistant copolymer). Itshigh elongation at yield and simultane-ously high stiffness and creep resist-ance help extend its application in thedesign of continuously-loaded, spring-elastic components.

Delrin® 300CP presents greaterdesign flexibility and freedom by com-bining high melt-flow with mechanicalperformance at levels that were, to date,only possible with polyacetals of consid-erably higher viscosity. This enables thereduction of wall thicknesses and mate-rial usage while maintaining load capac-

ity, the design of more complex compo-nents, or – at the same wall thickness –the use of longer flow distances. At thesame time, the low viscosity of the meltimproves weld line strength, therebyfacilitating tool optimization, e.g. theuse of several injection gates as well asshorter cycle times. Thanks to its highheat deflection temperature, Delrin®

300CP can be used at considerablyhigher temperatures than comparablecopolymers. The material does not needto be pre-dried, which is of additionalbenefit to the processor.

As is typical for all Delrin® poly -acetals, the new grade 300CP provideshigh surface hardness, very low wearand friction, resiliency and a highresistance to chemicals and solvents.Potential applications include automo-tive components (such as fasteners,seatbelt components, levers, brackets,gears and switches), buckles, latches orsurface parts for sporting goods, hard-ware for windows and doors, parts fordomestic and commercial irrigationsystems, as well as general compo-nents for snap-in joints.

New DuPont™ Delrin® 300CP combines high impact

resistance, even at low temperatures, with high stiff-

ness, strength and elongation at yield – yet it is particu-

larly efficient during processing, thanks to its relatively

low melt viscosity. The cost of the new resin is around

that of standard polymer grades, allowing for more

cost-efficient solutions. The broad range of potential

applications includes automotive components, sports

and leisure products as well as mass-produced articles.

DuPont™ Delrin® 300CP optimisesimpact performance, flow and cost-efficiency

DuPont™ Delrin® 300CPHigh impact-modified copolymerHigh viscosity copolymer20

40

60

80

100100

Mel

t Flo

w R

ate

Yield Stress Yield Strain

Tensile Modulus

Notched Charpy -30 °C


Promoting safer oven use By Elisenda Falcó and Oscar Gaona, DuPont Engineering Polymers,Spain

The ‘Impulse’ guide for Fagor ovens,

a system patented by Spanish

company Fagor Electrodomésti-

cos, is a totally new device for

oven cooking: by simply pulling

open the oven door, the hot oven

tray automatically slides out for safe

and easy access. The guide is mounted on a

support made of DuPont™ Zenite® and metal.

The new ’Impulse’ system to accesshot oven trays in ovens from FagorElectrodomésticos (Basauri, Spain)has been developed and patented bythe company with the support of Het-tich International. It includes self-extracting Quadro runners, whichallow total access to food withouttouching the oven tray. By simplyopening the oven door, the tray auto-matically glides forward with the food– when the door is closed, the trayslides back in. The operation of thisapplication relies on gravitational

force in order for the Quadro runners,mounted on stainless steel ball bear-ings, to glide out in a lineal move-ment. In order to achieve this, FagorElectrodomésticos worked with HettichInternational, a supplier of runner sys-tems, whose Spanish subsidiary, OBEHettich S.L., is based in Aizarnazábal(Guipúzcoa, Spain).

The runners have an end-cap madeof Zenite® liquid crystal polymer resin.The material, already widely used in theelectronic industry, was selected forthis application due to its benefits incooking. The particular grade ofZenite®, FG7145L BK011, is resistant tohigh temperatures, is approved for usein repeated food-contact applications,delivers high performance and anappealing surface finish.

“We were looking for a material forthe end-caps that could withstand thehigh temperatures encountered indomestic ovens, which can be as highas 240 °C (464 °F). Moreover, the partswere required to support the weight ofthe oven tray plus food, at simple com-pression and supported by a stainlesssteel guide, but this was no great chal-lenge”, explains Urtzi Zubiate, innova-tion leader at Fagor Electrodomésticos.“The sole mechanical stress the end-caps encounter is the impact againstthe oven’s door. The material needed to

be of sufficient strength towithstand the initial impactuntil the tray begins to glideback, yet it shouldn’t be ashard as metal, so as to avoidscratching the glass door.That’s how we arrived atengineering thermoplas-tics providing the bestpossible solution.”

Further unex-pected bene-fits weregainedthrough theadoption ofZenite®. Theseincluded the opportunity to achieve animpressive part thickness of 13 mm(0.5 inches) for a part which is 80 mm(3 inches) long, as well as the ability toassemble the stainless steel and plasticparts, without the need for additionalcomponents, for further cost savings.Indeed, with regard to cost, the reducedcost of tooling for the Zenite® partmakes it the most cost-effective alterna-tive. Fitting with the Quadro guide isideal, due to the high dimensional sta-bility of the end-cap’s neck, and theelimination of additional productionsteps – all of which will help make Zenite® the material of choice for applica-tions in other oven ranges in the future.

DuPont™ Zenite® LCP

� Temperature resistance� Food-contact approved� Surface finish

Contact

Fagor ElectrodomésticosUrtzi ZubiateInnovation Leader – Ovens BusinessAvda Cervantes, 45 48970 Basauri (Bizkaia) , Spain Tel.: +34 943 038 213uzubiate@fagorelectrodomesticos.comwww.fagorelectrodomesticos.com


Ball tables are industrial conveyors thatuse fixed balls to transport productsand materials by rolling instead ofusing a moving belt or chain. The balltables are made up from multiple balltransfer units, each consisting of alarge, load-bearing ball which sits atopsmaller balls inside a semisphericalmain body. Both ball tables and balltransfer units are designed for indus-trial and commercial applications thatrequire the transportation of bulk mate-rials, boxes, packages, or parts in apredetermined path, and that havefixed or selective points for loading and

discharging. The components of theball transfer units are usually made ofsteel, carbon steel, or stainless steel.

It was when considering the devel-opment of ball transfer units for thealignment of flat panel displays andsolar panels, that Japanese companyISB (Iguchi Kiko Co., Ltd. Tokyo), a sup-plier of quality ball bearing systems,discovered the requirement for a tailor-made solution for use in cleanroomenvironments. “Conventionally, solidpins are used to support the glassalignment process, which generate par-ticles and result in high friction due to

repeated, abrasive motion. There was astrong need to improve the process,”explains Hiroshi Kawai, marketingdepartment director at ISB. “Butnobody believed that ball transfer unitswould solve the problem because ofthe number of metal parts movingwithin them, which was seen as thesource of contamination by cleanroomprocess engineers.”

The solution lay in the adoption ofdifferent families of Vespel® parts forcomponents in ISB’s ISC range of balltransfer units for cleanroom applica-tions. Due to the high surface hardnessand stiffness of the Vespel® parts –including the main body, small ballsand large ball – their elastic deforma-tion, caused by the weight of the trans-ported material, can be controlled. Sim-ilarly, the high heat deflection tempera-ture of the Vespel® parts (above 300 °Cor 572 °F) also helps limit deformation.Consequently, frictional resistance tomovement of the transported materialis minimized, allowing it to be movedboth smoothly and accurately by asmall external force. The elimination of

Patented ball transfer

units, made using DuPont™

Vespel® parts and shapes,

are used for flat panel dis-

play and solar panel han-

dling. Combining low abra-

sion and low particle gen-

eration, the ball transfer

units from ISB (Iguchi Kiko

Co., Ltd.) enable smooth

and efficient operation in

cleanroom conditions.

400

300

200

100

10000

200 300 400 500 600

Used Ball Transfer

New Ball Transfer

Used Pin

New Pin

(g)

(1/100 sec)

Comparison ofCoefficient of Fric-tion betweenPEEK Pin and ISBBall Transfer

Smooth operatorBy Masayuki Yonezawa, DuPont Engineering Polymers, Japan

metal components from the ball trans-fer units helps remove the source of for-eign matter (e.g. metal powder result-ing from abrasion) which can poten-tially damage the delicate panels. Theexcellent erosion resistance of theVespel® parts prevents the depositingof chemical substances, further reduc-ing the risk of contamination. Excellentresistance to UV light or chemicalresistance are additional benefits, asHiroshi Kawai confirms: “By selectingVespel® as the key material for our ISCrange of ball transfer units, we haveobtained particularly good resultswhen using the units in pretreatmentdevices for a liquid-crystal panel sub-strate glass, such as a vacuum cham-ber, or a heating oven.”

Over a six-year period, DuPont inJapan worked with ISB on selecting thebest material and technical solution tomeet the needs of flat panel displayand solar panel manufacturers. A rangeof Vespel® series are used in the ISCball transfer units, including those fromthe Vespel® TP-8000 family of finishedparts and shapes, whose high purityand resistance to plasma and heatmakes them well suited for uses withinthe semiconductor industry. The mate-rial is weldable and wear resistant andmaintains its good dielectric propertieseven at permanent operating tempera-

tures of up to 200 °C (392 °F). OtherVespel® series used include Vespel®

SP-202, which decreases electrostaticloading in the manufacturing and han-dling of flat glass panels for liquid crys-tal displays and is ideal for use withproducts that are handled in high-tem-perature, vacuums or reactive environ-ments. Vespel® SCP-5000, whose ben-efits include ultra-high purity and highstiffness, and Vespel® SP-1, deliveringexceptional wear resistance, insulation,and a low coefficient of friction, com-plete the list of DuPont materials used.

“The proven performance ofVespel® parts and shapes in highlydemanding semiconductor applica-tions, in terms of their purity, wearresistance and wide range of thermalresistance, was one principal reason towork with DuPont,” explains KaoruIguchi, president of Iguchi Kiko (ISB).“The other is the strong emphasis ondevelopment support for the materialand testing. With the cooperation ofDuPont, we were able to acceleratedevelopment faster than ever before.”

According to Iguchi, flat panel dis-play and photovoltaic manufacturingengineers have boosted their produc-tivity by using the ISC range of balltransfer– indeed their application hasextended from flat panel display andphotovoltaic manufacture in Asia to

parts of North America. In 2005, NikkanKogyo Newspaper awarded the ‘ISCBall Transfer for Cleanrooms’ with the“Japanese Brand Award” for its innova-tive solution in flat panel manufactur-ing. In 2007 ISB & DuPont’s joint patentfor the ball transfer unit and ball tablewas granted in the U.S. “With DuPontas a key development partner, we willcontinue to develop new products, newapplications, and new markets,” con-cludes Kaoru Iguchi.


Contact

Iguchi Kiko Co., Ltd. (ISB)1-20-7, MinamiohizumiNerima-kuTokyo178-0064, JapanTel. +81 3-3923-1211Fax +81 3-3923-8100www.isb-iguchi.com

DuPont™ Vespel®parts and shapes

� Wear resistance� Temperature resistance� High purity

www.plastics.dupont.com

Crastin®

pbt

thermoplastic

polyester resin

Delrin®

acetal resin

Hytrel®

thermoplastic

polyester elastomer

Minlon®

mineral reinforced

nylon resin

Rynite®

pet

thermoplastic

polyester resin

Thermx®

pct

high performance

polyester

Tynex®

nylon

monofilament

Vespel®

parts and shapes

Zytel®

nylon resin

Zytel®

htn

high performance

polyamide

Zenite®

lcp

liquid crystal

polymer

DuPont™ etpv

thermoplastic

rubber that resists

oil & heat

The DuPont Oval Logo, DuPont™, The miraclesof science™, and Crastin®, Delrin®, DuPont™ETPV, Hytrel®, Minlon®, Rynite®,Thermx®,Tynex®, Vespel®, Zytel®, Zenite® areregistered trademarks or trademarks of E.I. duPont de Nemours and Company or itsaffiliates.

Publisher: Evelyne SchützDuPont Engineering Polymers2, ch. du PavillonCH-1218 Le Grand-SaconnexGenevaSwitzerlandTel.: +41 22 717 51 11Fax: +41 22 580 22 35

Editor: Andrew Wilkins [email protected]

Layout: Konsens PR GmbH & Co. [email protected]

Engineering Design is published in English,French, German, Italian, Portuguese,Russian and Spanish by Du Pont de Nemours International S.A.P.O.Box 50, CH-1218 Le Grand-SaconnexGeneva,Switzerland.

The information set forth herein isfurnished free of charge and is based ontechnical data that DuPont believes tobe reliable. It is intended for use bypersons having technical skill at theirown discretion and risk. DuPont makesno warranties, express or implied, andassumes no liability in connection withany use of this information.

© 2009 E.I. du Pont de Nemours and Company

Printed in Switzerland

L-14406-00

To get Engineering Design in an e-format, go tohttp://www.engineeringpolymers.com/engdesign/

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engineering design 2009-1 english - dupont engineering design 2009-01 ... crastin® and dupont...

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