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Martin Pilař DuPont Performance Materials AUTOMOTIVE Applications & Development Martin Pilař Polymercoach 2016 Value Proposition and Business Model Enhance customers’ product performance, improve sustainability and reduce total downstream system cost Design: Work Materials: Create new together with our formulations when customers to enlarge new properties possibilities Inclusive are required Innovation Processing: Work together with customers to optimize process efficiency with our products Expert Applications Development Automotive Key Trends impacting DuPont Light weighting of the vehicle Tailpipe emission control systems Noise (68dB A) and Safety Regulation H&EV powertrain adoption Renewably sourced materials and sustainable design Engine downsizing and efficiency improvements More severe conditions in Engine compartment Environment Comfort and perceived image / brand Increased warranty length Fuel efficiency Consumer Standardization and modularity in design Global networking and source where the growth is Cost competitiveness Economics 2 DuPont Market-Back Innovation for Automotive CO2 Emission is the Most Significant CHALLENGE Faced by Car Manufacturers Lightweighting Sustainability Efficiency Electrification Engine Downsizing 3L V6 Non Turbo 2.4L 4 Cylinder OEMs are removing cylinders (6 to 4, 4 to 3, even 2) Turbo and reducing engine displacements Turbo charging has reduced weight of 200 HP AIM by ~50% 4 Air Induction and Turbo-charging Increased Engine Temperatures Electrification / Hybrid Vehicles Lightweighting Innovation 5 Thermoplastics Composites solutions Vizilon® 6 Automotive - Powertrain •Air ducts and resonators High Temperature Air •Turbo Charger Hoses Metal Replacement •Throttle bodies High Performance Acid Resistance •Air intake manifolds Oil exposure •Oil pans Durability •Oil modules •Rocker covers • •Engine Sealing •EGR Systems •Front covers •Transmission Hytrel® Vamac® Zytel® HTN Zytel® PLUS Zytel® PA66 + PA6 Zytel® RS Automotive - Powertrain Lightweighting with Plastics, Weight savings in Engine Applications … Material Science advances Rear camshaft retainer: 0.2 kg Manifold: 1.0 kg Charge air cooler: 1.0 kg Turbo duct, hose: 0.5 kg Oil pan: 1.0 kg Cooling system: 0.8 kg Rocker cover: 0.5 kg Engine cover: 1.0 kg Cylinder head cover: 4.5 kg Pumps, throttle body, small components: 0.5 kg Eliminating just 11 kg on 70 million light-vehicle engines could save more than 900 million liters of fuel Data: DuPont Powertrain Rocker Covers Chrysler BMW 1977 1990 1995 NOW First RC Porsche Boxer BMW M52 -First high New generation 2K prototype First EU RC mass, high complex gasket for radial already in 2k Fastest SOP ever system : 30% weight sealing ? 30% weight saving saving (and attractive Cost saving cost saving) Moving to the lower part of the engine Oil Pans 1980 2000 2008 2010 NOW First prototype Functional First commercial Functional Integration of oil in the US protos in EU part (Bruss for integration pick-up pipe, oil Daimler) (ElringKlinger) level switch, oil filter and other oil return Components or even oil pumps. Air Intake Manifolds are one of the highest volume applications for engineering plastics 1987 1990 1995 NOW DuPont Troy GM introduces World’s largest Air intake manifolds to Machines 3800 Manifold AIM for Ford integrate more functions in DuPont Zytel® prototypes Mustang In PPA for thinner walls, with 2 –piece DuPont Zytel® welded design. higher temperature The charge-air cooler is incorporated into the intake manifold (VW) Integrated AIM/CAC Source: Source: Mahle Magazine No D duct (CAC to AIM) / shorter C duct (TC to CAC) with higher temperature exposure… Automotive Development Application Profile Application: • Air ducts BMW Engineering polymer: • Hytrel® HTR4275 Benefits: • Easy processing with blow molding • Pressure pulsation performance at high temperatures • Excellent weldability • Blow by gas resistance Turbo Hoses - Hot Side Air Duct • Commercial Application Zytel® 70G35HSLX - Injection moulded Zytel® BM70G20HSLX - Blow moulded Zytel® 70G35HSLX Injection moulded + welded shells Vamac® / Kevlar® / Vamac® HP welding FKM/ VMQ / Nomex® / VMQ Copyright © 2015 DuPont. Hytrel®, Crastin®, Zytel®, Vamac®, Kevlar® and Nomex® are trademarks or 15 15 registered trademarks of E.I. du Pont de Nemours and Company or its affiliates. All rights reserved. Lightweighting with High Temperature Plastics, in Transmissions Valve body cover: 2.50 lb Transmission control module: 1.00 lb Gasket: 0.50 lb Automatic transmission fluid level valve: 0.25 lb Automatic transmission fluid filter body: 0.50 lb Range sensor: 0.25 lb Valve body: 4.00 lb Hydraulic Accumulator: 1.20 lb Case baffle: 0.50 lb Differential baffle: 0.50 lb Additional, proprietary development programs: 5.00 lb DRIVELINE IS ANOTHER 15 lb and those ARE IN DEVELOPMENT Eliminating just 5 to 7 kgs on the 40 million automatic transmissions globally would save 340 million litres of fuel Transmissions- real need for weight saving Electronic transmission control system & modules Zytel 70G35 HSLX Transmission oil pan Zytel 70G35 GM 6-Speed transmissions use Seals in Vespel Hytrel® for ATF baffle and seal – to reduce fluid aeration and allow fluid-fill for life. Next switch from metal to plastics ? Engine Front Covers ? Transmission Front Housing ? Exhaust Mufflers ? Dual mass fly wheel ? Manual transmission Forks ? Converter wheel ? High Temperature Polyamides 230°C 220°C 210°C 200°C Performance 190°C Zytel® Zytel® 70G35HSRX 70G35HSLX 180°C Zytel® 70G35HSLRA4 160°C Zytel® New product development 73G30HSL Price Automotive – Thermal Management Downsizing •Thermostat & Heater Housings Durability • •Outlets/Inlets, Lightweight •Coolant tubes High Efficiency •Valves, Cross overs •Coolant Pumps •Water Jacket Spacers •Charge Air Cooler •Radiator end tanks •Fan shrouds •HVAC Zytel® HTN Zytel® PA66 + PA6 Zytel® RS Automotive – Thermal Management Thermostat Housings / Water Outlets: ZYTEL® HTN (PPA) Benefits/Features: Excellent Resistance to Hot Long Life Coolant. Minimal creep to maintain sealing surface Dimensional Stability for strength around bolt inserts Cost and Weight $avings vs. Aluminum, and PPS 12000 Lower Aromatic HTN51 Content than HTN 9000 PA6T/6I/66 6000 PA66 3000 Tensile Modulus Aged, MPa Aged, Modulus Tensile 50% G05 LLC, 130 oC,3000 hr 0 0 10 20 30 40 50 60 Stress at Break after Aging, MPa ZYTEL® HTN51G35HSLR or HTN51G45HSLR General pres Water Pump Housings and Impellers Zytel® 70G30 HSLR PP GF45 Citroen C3 Bergstrom Zytel® PLS90G30 PA66GF30 Zytel® HTN51G35HSLR Toyota Electric pump David CRAIG PTY Automotive – Interior Noise Air Quality • Door Systems Lightweight • Safety Restraint Systems Safety • Seating Systems Comfort • Airbag Systems • Dashboard Systems • Storage and Trim • Gear shift • Turn signals Crastin® Delrin® Delrin® LE Hytrel® Hytrel® RS Sorona® EP Zytel® PA66 + PA6 Zytel® RS Automotive – Interior Polyacetal parts used in the interior Sunroof Safety System - Sliding Guide - Seat Belt Button Door Panel - Window Motor - Retentioner - Door Lock System - Window Regulator - Child Seat Seats - Clip, Fastener - Seat Adjuster - Headrest Tubes Front Panel - Heater Fan / AC - Speedometer - Switches - Audio/GPS - Airbag System Car manufacturer interior emission requirements VDA 275* HCHO Emission Many Delrin® standard OEM (mg/kg) grades meet the VDA 275 Audi < 2 requirement of <10mg/kg while Delrin® E grades BMW < 2 meet the <2mg/kg limit Daimler < 2 Ford < 5 GM/Opel < 5 PSA < 10 Renault < 10 Volkswagen < 2 * or equivalent Delrin® Acetal Homopolymer – Grades with Low (<8 ppm) and Very-Low (<2 ppm) VOC Emissions High Molecular Weight Medium-High Viscosity Medium Viscosity Flow Series High Performance Balance of Features Good Flow General Use, High Performance, General Use, High Performance, General Use, High Performance, Low Emissions Very Low Emissions Low Emissions Very Low Emissions Low Emissions Very Low Emissions Characteristics (<8 ppm) (<2 ppm) (<8 ppm) (<2 ppm) (<8 ppm) (<2 ppm) Very Low Emissions Grades (Automotive) 100P 300CP 500P Standard, Unmodified Grades 111DP 100PE 311DP 300PE 511DP 500PE UV Stabilized 127UV 127UVE 327UVE 527UV 527UVE 100T 100TE Toughened 100ST 100STE 300TE 500T 500TE Low Wear and Friction 100AL Coming next: Delrin® 111PE – creep resistant high viscosity Delrin® 511PE – creep resistant medium viscosity Delrin® 911PE – creep resistant low viscosity Delrin® 100ALE – improved wear and friction high viscosity Automotive Development Application Profile Application: • Interior Door Handle Engineering polymer: • Minlon® 73M40 Benefits: • Excellent surface aspect for chrome plating • Dimensional stability • Stiffness and impact performance Automotive - Exterior Recyclability Durability • Light weighting Styling versatility Safety • Lighting • Fascias and Panels • Roof Accessories • Wiper Systems • Exterior Trim • Wheels & wheel covers Crastin® Delrin® Hytrel® Sorona® EP Zytel® Zytel® HTN Automotive - Exterior Successful CRASTIN® projects Application: VW Sharan VW Touran • Head lamp bezels Audi A4 Engineering polymer: • Crastin® Benefits: • Low outgassing • Excellent surface quality • High flow PBT, ease of processing • Temperature performance and durability Successful CRASTIN® projects OEM - model: AUDI Q3 Application: Headlamp Bezel Product: CRASTIN® CE2055 SOP: 2014 Successful CRASTIN® projects VW Sharan VW Touran OEM - model: ŠKODA Octavia Application: Headlamp Bezel Product: CRASTIN® CE2055 ŠKODA Octavia - Headlamp Bezels VW Sharan VW Touran ŠKODA Yeti - Headlamp Bezel VW Sharan VW Touran OEM - model: ŠKODA Yeti Application:
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