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 TrendsKey Automotive DuPont impacting
Economics Consumer Environment Regulation Cost competitivenessCost wh andsource networking Global design in and modularity Standardization efficiency Fuel length warranty Increased brand / image perceivedand Comfort compartment Engine in conditionssevere More improvementsefficiency and downsizing Engine Renewably adoption H&EV powertrain (68dB Noise Safety and A) Tailpipesystemscontrol emission vehiclethe of weighting Light sourced
materials and sustainable design and sustainable materials
ere is thegrowth
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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 180°C Zytel® 70G35HSLX 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: Headlamp Bezel
Product: CRASTIN® CE2055
SOP: Q1 2014
Mercedes GLA - Headlamp Bezel
VW Sharan VW Touran
OEM - model: Mercedes GLA
Application: Headlamp Bezel
Product: CRASTIN® CE2055
SOP: Q1 2014
Mercedes CLS - Full LED Module
VW Sharan VW Touran
OEM - model: Mercedes CLS
Application: Full LED Module
Product: CRASTIN® LW9330 BK851
SOP: 2011
Automotive - Electrical & Electronics
• Sensors & Solenoids Safety Regulation • • Connectors Fuel Efficiency • HEV & EV System High Performance Down Sizing • Ignition Systems Cost Reduction • Motors & Actuators Comfort • Control Modules • Relays & Switches • Steering Wheel Module • Wire & Cable
Crastin® Delrin ® Hytrel® Sorona® EP Rynite® Vamac ® Zytel® HTN Zytel® PA610+ PA612 Automotive - Electrical & Electronics Automotive - Chassis
• CVJ boots • Jounce Bumper Emission Reduction Durability • Fuel Systems • Fuel Efficiency • Engine Mounts • Brake & Suspension Driving Performance Comfort • Fluid hoses and tubing • Fasteners • Exhaust Muffler • Pedals & Gearshift • Steering Systems
Delrin® Hytrel® Vamac® Zytel® Zytel® RS Zytel® HTN Automotive - Chassis Hytrel® solution to replace Foam PU Jounce Bumper
Hytrel® Jounce Bumper Current injected Foam PUR By specific thickness solution Thermoplastic profile, Hytrel® Jounce Elastomer Bumper design can Hytrel® absorb maxim energy
Blow Bellows molding design process First commercialization: Replacement of PUR on Fiat Punto
Polyurethane foam
Hytrel® Hytrel® vs. PUR foam: Significant cost reduction
Polyurethane foam : 4 parts Hytrel® : 1 part
Base cup No Base cup
POM/Rubber Ring No Ring
Jounce Bumper Jounce Bumper integrated with Dust Cover dust protection
• Less assembly cost (integration, less parts) • Low tool investment (blow molding tool) • Low machine investment (Ossberger machine) • Less part reference (1 instead of 4) • Fast cycle time (from 20s to 30s) • Recycle resin (regrind about 30%) • …
6/21/2016 We Continue To Fuel The Automotive Industry With Innovative Solutions
+100 yrs Automotive Industry is a strategic market