Powertrain and Engineering Plastics - DuPont USA | … c… · Powertrain and Engineering Plastics ... DuPont Automotive Oil Pan Global Segment Manager Germany ... Modeling Analysis

Powertrain andEngineering PlasticsMaterials to Reduce Mass and Boost Performance

Franz SpitznagelDuPont Automotive Oil Pan Global Segment ManagerGermany

Patrick GranowiczDuPont Automotive Engine Covers Segment Manager Troy, MI

What we’ve learned,where we can go together…

2

Contact – Dial DuPont First 1.800.441.0575; www.automotive.dupont.com

Engine Design and Function –a 30 Year Revolution in Engineering Plastics

We’ve come a long way!

http://www.spiegel.de/auto/aktuell/0,1518,grossbild-439811-343264,00.html

3


Engineer’s Dreams … Plastics’ Possibilities

Add function, not mass….....Lower tooling cost…………..Achieve 100% reliability…….Integrate parts for low cost ..Beat the heat ………………....Improve ease of assembly....

Improve performance…….…

Weight reduction ~ 40%<½ the tooling costPredictive EngineeringMulti-function design easeIntegrated engine cooling

Snap fits, packaging viacomplex geometriesImprove fuel economywith lower emissions,reduce NVH

4


Engineering Plastics Firsts in Powertrain

1980

EmissionsCanister

Fan

GOR and ShroudsExpansionTanksAIM

1985 1990 1995 2000 2005 2010

Cyl. Head CoversAC PulleyAir ducts

New AIM

Hot-side Air Ducts

Water Pumps

Oil PanFront coverIntegrated AIM-EGR

Turbo chargers

ExhaustEGR Cooling Muffler System

ResonatorsAir –IntakeManifolds

DuPont materials examples for ICE– from the past to the future

5


Sheet MetalSheet MetalAluminum die castAluminum die cast

Al sand castAl sand castMgMg

ZYTELZYTEL®® 35% GF35% GF

Wall thicknessWall thicknessDensityDensityWeight factorWeight factor(SG*Th)(SG*Th)

00

33

44

55

66

77

88

99

1010

22

11

Zytel® vs. Metal - Weight Factor

6


Tooling lifetime

Investment production unit

Flexibility in production

Part cost

T-Plastic ++ - +++ 1

Die Cast AL

-- + ++ 1.2

Sand Cast AL

--- -- --- Quantity dependant

Die Cast Mag

-- + ++ 1.4

Sheet Metal

+++ +++ --- 0.8*

* high quantities f.e > 1MM

Key: + higher; - lower

Cost and Productivity Comparison

7


1977 1990 1995 2010

First Rocker Cover prototype

already in 2k

Porsche Boxster-First EU Rocker

CoverFastest SOP ever30% weight saving

Adequate costsaving

New generation2k gasketfor radial

sealing??

MucellTechnology

Powertrain Engine Cylinder Covers

BMW M52 -First high mass, high complex system

30% weight saving

Attractive cost saving

Chrysler

8


1987 1990 1995 2010

Air Intake Manifolds are One of the Highest Volume Applications for Engineering Plastics

DuPont Troymachines prototypesand installslost coreprocessin Troy lab

GM introduces3800 Manifold in DuPont™ Zytel®with 2 –piecewelded design.

Porsche launches 1st European AIMIn DuPont™Zytel®

Air intake manifold in HTN PPA tointegrate more functionsand high EGR temps for thinner walls, higher temperature.VW: The charge-aircooler is incorporatedinto the intake manifold

World’s largestAIM for Ford Mustang In DuPont™ Zytel®

9


1980 2000 2008 2011

Continuous Improvement in Weight, Cost Savings with Performance Increases for Oil Pans

2009

First prototypes-

1977 in U.S.

Functional prototypes

in E.U.

First commercial part

for Daimler made by Bruss

2nd generation with functional

integration made by Elring

Klinger

o

3rd generation module with full

integration made by

Mann+Hummel

10


Air ducts, from - 40°C to + 210°C Hytrel® and Zytel® blow molding -

great tools for cost and weight

Bracket Assy.

Pipe

Hose Assy.

Clamp

Hose

Duct AssemblyTotal Weight 2.8kg

11


6-8 Speed Transmissions - Real Need for Weight-Savings

Transmission oil panZytel® 70G35

Electronic transmission control system & modulesZytel® 70G35 HSLX

Seals in Vespel® partsGM 6-Speed transmissions use Hytrel® for ATF baffle and seal –to reduce fluid aeration and allow fluid-fill for life.

12


New Opportunities for Weight Saving with High Performance Plastics

Front cover, Zytel®;Zytel® HTN PPA Turbocharger housing

Super-tough Zytel®+ Zytel® HTN PPA

EGR Cooler unitsZytel® HTN - PPA

Toyota PriusZytel®HTN51G35HSLR Plastic muffler in Zytel® HTN PPA

13


New Powertrain Trends

CO2 / Emissions Influence Change• Small engines - down to 2 cylinder

• Effective ICE fuel consumption

• Bio-fuel

• HEV, EV, Hybrid diesel plus “clean” fuel

• Turbos/Bi-turbos for small diesel and fuel engines

• Modular approach for efficiency & savings (VW approach)

14


DuPont Technical Support

Material DevelopmentProcess Development and Processing SupportApplication Development SI ProcessDesign Assistance

InnovativeSystem

Solutions

Processing

Design Material Formulation

15


DuPont Engineering Polymers CAE Resources

Unigraphics

Solid-Works

PATRAN

ANSA

HYPER MESH

CATIA

Moldflow

ABAQUSANSYSMARKLS-DYNAMoldflow

Local Workstations

High Performance LINIX Cluster

Modeling

Analysis

Hardware

16


DuPont Engineering Polymers CAE Solutions

Injection Molding Analysis• Filling• Cooling• Shrinkage• Fiber Orientation• Warpage

Structural AnalysisStatic StressDynamic StressImpact

NVH AnalysisAcoustic FrequencyResponseNoise RadiationNoise Penetration

17


World’s 1st Pass-Car Oil Pan in NylonWinner – 2008 SPE Most Innovative Use of Plastics Award

Daimler 4 cylinder diesel engine oil pan DuPont™ Zytel® 70G35 HSLR A4

Integration in future oil pan models could include: oil pick-up pipe, oil level switch, oil filter and other oil return components or oil pumps.

18


Accelerations

0.02.04.06.08.0

10.012.014.016.018.0

812

1117

1422

1728

2033

2338

2644

2949

3255

3560

3865

4171

4476

[rpm]

Acc

eler

atio

n [m

/s2]

Order 2.5Order 3Order 4Order 6.5

Mold Filling

Dynamic Structural Analysis

Impact AnalysisCAE Tools for Daimler Oil Pan

19


Materials: Where We Can Go With You …• CaCL resistance• Dimensional stability• Electrical friendly resins • Flammability to V0• Greater heat resistance• Hydrolysis resistance• Renewably Sourced

• e.g. Zytel® RS 6,10 resin (47% renewable content) for radiator end tanks

• Super productivity materials• OTHER NEEDS?

Denso radiatorend tanks of Renewably Sourced Nylon 6,10

More than 1/3 of our product offering is new over the past 5 years

20


Materials Choice is Driven by Engineering NeedsPe

rfor

man

ce

Cost

Tefzel®PTFE

Zytel®Hytrel®

Crastin®

Zytel® HTNPPA

Zenite®LCP

Vespel®PI

Vespel®PIVamac®/Viton®

Elastomer

Minlon®Crastin® PBTRynite® PET

21


High Temperature Heat Aging - Polyamides

Zytel®70G35HSLRA4

Zytel®HTN PPA

New DuPont PA material family

coming in 2010

High Performanceresins family

<160°C

<180°C

<190°C

<200°C

<220°C

>220°C

DuPont resins for Powertrain

Zytel®70G35HSLX

Zytel®EFE 270056

22


Choosing the Right Material for the Right Reasons

2

4

6

8

10Processing window

Surface appearance

AOA heat aging 170°C, 1000h

AOA heat aging 150° C,3000h

Hot oil resitance

Glycol resitance

Chemical Resistance

Warpage

Dimensional stability

Thoughness

HSLB HSLR HSLX HTN

Zytel® 70G35 grades, Zytel® HTN 51G35

23


Superflow, Superstiff and Mucell®Materials

Super flow material for thin wall technology Zytel® 70 G35 HSLRA4

24



Super Stiff material for Structural Applications Zytel® HTN 51LG50

25


2

Mucell® for weight savings and productivity gains


26


Lohner Porsche: the first hybrid vehicle

Ferdinand Porsche built the first standard hybrid power unit in 1900.

His Lohner-Porsche featured a combustion engine as well as an

electric hub motor and could store energy in a battery.

The World's First Hybrid Vehicle

Tesla: the first full electrical sports car

Stay Tuned forthe Upcoming SegmentVehicle Electrification

27


Materials to Help Electrify Vehicles

Hitoshi ShioyaDuPont Automotive Global Electrical &

Electronic Applications Segment Leader

Paul KaneDuPont Automotive Global Electrical & Electronic Senior Development Programs Manager

28


Copyright © 2009 DuPont. The DuPont Oval Logo, The miracles of science™, DuPont™, Zytel®, Hytrel®Vespel®, Mucell®, Tefzel®, Minlon®, Rynite®, Zenite®, Crastin®, Vamac®, and Viton® are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.

Because we cannot anticipate or control the many different conditions under which this information and/or products may be used, neither DuPont nor the authors guarantee the applicability or the accuracy of this information or the suitability of its products in any given situation. Users of DuPont products should make their own tests to determine the suitability of each product for their particular purposes. The data listed herein falls within the normal range of product properties but they should not be used to establish specification limits or used alone as the basis of design. Disclosure of this information is not a license to operate or recommendation to infringe a patent of DuPont or others.

CAUTION: This product is not permitted to be sold for use in medical applications involving implantation in the human body or where contact with internal body fluids or tissues will equal or exceed 24 hours. For applications involving contact of less than 24 hours, see “DuPont Medical Caution Statement,” H-50102 or contact your DuPont sales representative.

29


Documents

Powertrain and Engineering Plastics - DuPont USA | … c… · Powertrain and Engineering Plastics ... DuPont Automotive Oil Pan Global Segment Manager Germany ... Modeling Analysis