2004 Detroit Auto Show: First North American High-Volume Thermoplastic Valve Cover Debuts on 2004 Chrysler and Dodge Minivans

TROY, Mich., Jan. 5, 2004 -- North America's first high-volume thermoplastic valve cover debuts on the 2004 Chrysler Town & Country, Dodge Caravan and Grand Caravan with 3.3- and 3.8-liter V-6 engines.

Made of DuPont(TM) Minlon(R) mineral reinforced nylon and manufactured by Bruss Sealing Systems, the elegantly styled valve cover reduces weight by more than 65 percent and cuts cost significantly compared to metal. The innovative thermoplastic valve cover also delivers benefits through integrated functionality: an integrated air/oil separator significantly reduces the amount of oil pulled into the engine to reduce environmental impact; an integrated PCV (Positive Crankcase Ventilation) valve housing helps reduce evaporative emissions and ensures the PCV system stays secure.

A dedicated global team from Chrysler Group, Bruss and DuPont Engineering Polymers ensured this program went from CAD drawing to commercial launch in just under 22 weeks. Implemented as a running change, the rapid development ensured the benefits of thermoplastics were delivered in the current vehicle model year.

"Use of thermoplastic in high-volume valve cover applications for North American manufacturers in the North American marketplace has been a long time coming," said Michael Cuneo of Bruss North America, a division of G. Bruss GmbH, Germany, and a leading thermoplastic valve cover producer in Europe. "Some of the smaller, focused programs that commercialized in the Americas through Japanese and European car makers recently helped the industry adopt the technology."

The valve cover is made of a specially formulated grade of glass/mineral reinforced Minlon(R) that delivers an excellent balance of stiffness, strength, dimensional stability and warpage resistance to meet stringent requirements for the application. DuPont also supported the development with CAE, moldflow, warpage, structural and modal analysis, helping to eliminate the costly and time-consuming prototype phase.

"Today's automotive industry requires systems and components that reduce weight and improve function," said Pat Granowicz, DuPont Automotive Engineering Materials engine cover development specialist. "Using Minlon(R) mineral reinforced nylon helped reduce weight, enable integration for greater functionality and clearly demonstrates how thermoplastic composites can speed innovation."

Switching to thermoplastics made it possible to eliminate the costly e-coating process along with several secondary machining steps. Minlon(R) runners and scrap from the injection molding manufacturing process also can be easily melt recycled.

DuPont is a science company. Founded in 1802, DuPont puts science to work by solving problems and creating solutions that make people's lives better, safer and easier. Operating in more than 70 countries, the company offers a wide range of products and services to markets including agriculture, nutrition, electronics, communications, safety and protection, home and construction, transportation and apparel.