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Zytel® Nylon Debuts on High-Performance BMW Motorcycle

High-Pressure Oil Tank of DuPont„ Zytel® Nylon Debuts on 
High-Performance BMW Motorcycle

DETROIT, April 11, 2005 €“ BMW€™s first full-bore sports motorcycle comes
ashore this Spring equipped with a high-pressure oil tank that underscores
the potential of DuPont„ Zytel® nylon for enabling innovation by meeting
challenging requirements.  The Mahle Group, Stuttgart, Germany, developed
the tank for BMW. 
The same engineers who developed the innovative double-longitudinal link
front suspension of the BMW K 1200 S found that the ideal location for the
oil tank is behind the motorcycle€™s engine in the rear subframe. 
€œThe oil-tank for the K 1200 S is a critical part from a safety point of
view,€??? said Jörg Stange of Mahle€™s OEM marketing department. €œIt must stay
leak-proof in normal use throughout the lifetime of the motorcycle. If oil
were to leak from it and drip onto the rear wheel, severe falls could be the
result.  That is why we chose Zytel® 70G35 HSLRA4, a resin tested and proven
in our own company.€???
The tank is designed to contain 2.8 liters of hot oil at operating
temperatures ranging from €“30 to +90ºC with peaks up to 140ºC.  It is
engineered to resist internal pressure of 3 bar (44 psi) at 23ºC in case the
tank is accidentally overfilled.
Mahle selected DuPont„ Zytel® 70G35 HSLRA4 to meet requirements for high
stiffness, strength and resistance to hot oil.  The resin is based on
heat-stabilized nylon 66 polymer with 35 percent glass fiber reinforcement.
The Zytel® resin delivers additional benefits in cost and appearance,
according to Stange. €œThanks to the melt€™s easy-flow properties, Zytel® can
be processed very cost effectively,€??? Stange adds. €œThat is particularly
important for this oil tank, because we produce the cover and the main body
together in a single tool. The good flow characteristics also contribute to
the part€™s high-class surface finish, which is a requirement for this highly
visible part.€??? The two parts are subsequently joined by vibration welding.
Zytel® resin produces an attractive, finished exterior surface, which is
important because the oil tank is in a visible location, and BMW customers
will expect unparalleled attention to detail when the motorcycle begins
arriving in dealer showrooms in April.
The oil tank for the BMW K 1200 S is a key component in its dry-sump
lubrication system, adapted from designs originally developed for racing
cars.  This technology offers maximum oil flow even under extreme
conditions, such as hard cornering loads or the bike€™s top speed of more
than 170 mph, according to BMW, and it has the additional benefit of
reducing engine height by doing away with the need for an oil pan.
The Mahle Group, established 80 years ago, is a major international
manufacturer of high-performance parts and systems for the automotive
industry.  The product range includes pistons and motor components, filter
systems and valve actuation systems.  With some 30,000 employees at 60
locations in Europe, America and Asia, Mahle has a global presence.
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