DuPont Applications Top SPE 'Most Innovative Use of Plastics' Awards in Chassis/Hardware and Powertrain Categories
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TROY, Mich., Nov. 12, 2004 -- DuPont materials helped Chrysler to secure the top Chassis/Hardware award, and Ford to win a Powertrain finalist award at Wednesday night's Most Innovative Use of Plastics Program, hosted by the Society of Plastics Engineers Automotive Division.
"DuPont is proud to work closely with automakers and the value chain to drive valuable innovation programs," said Chris Murphy, automotive director - Americas, for DuPont Automotive Performance Materials. "These two metals- replacement projects, which are on the road right now, demonstrate the numerous automotive opportunities yet remaining for thermoplastic materials. In combination with smart engineering, these materials continue to provide significant weight savings, cost reduction and performance benefits."
The Chrysler Group, Mayco Plastics and DuPont Automotive earned the top award in the chassis/hardware category for using thermoplastic in a mirror- housing bracket -- the first use of plastic for structural support of a sheet metal body panel at the body in white stage. The bracket, located between the inner and outer door panels to support the driver- and passenger-side exterior mirrors, debuts on the second-generation 2004 Dodge Durango SUV and Dakota pickup.
The application provides significant savings on the cost of each part by eliminating costly multiple steps in the manufacturing process, eliminating the need for an additional welding cell on the assembly line and significantly reducing EHPV (engineering hours per vehicle) in the plant.
"The weight, cost and EHPV savings alone make this a breakthrough application," said Sandeep Vijaywargiya, Chrysler Group truck products engineer, who accepted the award for Chrysler. "The fact that this is the first use of plastic to reinforce non-crash body panels opens up a whole realm of possible automotive applications."
The bracket is made of DuPont(TM) Rynite(R) PET due to its resistance to creep, load, torque and its ability to take brutal e-coat oven temps of 350 degrees for an hour. The material also had to resist weather and harsh chemicals and withstand durability testing, including a torture test that slams the vehicle door 50,000 times.
A team from Ford; Cascade Engineering, Grand Rapids, Mich.; Roush, Livonia, Mich.; and DuPont Automotive were named Powertrain category finalists for "supersized" intake ducts that debut on the 2005 Ford F-Series Super Duty. This new one-piece, seamless duct replaces four aluminum and silicone parts to eliminate leak paths; to reduce tooling, labor and overall costs up to 33 percent; and to improve airflow between the turbo-charger and the engine inlet for improved engine performance. The new one-piece duct also reduces weight by more than 60 percent -- 3.3 pounds per truck. The design also improves ergonomics for assembly operators.
The new duct employs a computer-controlled process -- 3D sequential co- extrusion blow molding -- and DuPont(TM) Hytrel(R) thermoplastic elastomer to produce in one step a unique, complex, engine-hugging shape that combines the qualities of hard and soft composites.
"This is a great example of the benefits that can be delivered when the whole value chain works closely from the start," said Andy Clark, technical engineering manager for Cascade Engineering. "This has been a true partnership, with DuPont acting as the glue to bring us all together."
DuPont(TM) Hytrel(R) thermoplastic polyester elastomer is used in this application due to its unique hard/soft characteristics. Hytrel(R) remains pliable in sub-freezing temperatures, for performance during cold startup, while surviving exposure to temperatures of 300 degrees Fahrenheit -- all while withstanding the high operating pressures generated by the diesel engine's turbocharger.
The Society of Plastics Engineers has been celebrating innovation with this awards program for 34 years.
DuPont is a science company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture, nutrition, electronics, communications, safety and protection, home and construction, transportation and apparel.
The DuPont Oval, DuPont(TM), The miracles of science(TM), Rynite(R) PET and DuPont(TM) Hytrel(R) thermoplastic elastomer are registered trademarks or trademarks of DuPont or its affiliates.
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