Innovative Design Helps Ford Five Hundred Keep Its Cool

WALWORTH, Wis. and THE WOODLANDS, Texas, June 24 -- As Ford's engineering designs heated up for its new flagship sedan, the company and its suppliers found an innovative way to keep things cool. In an effort to maximize space in the engine compartment, Ford utilized a new design for the Ford Five Hundred's cooling system. Driven off one of the overhead camshafts, the new direct drive water pump reduces part count (and corresponding costs) by integrating the sedan's thermostat housing. This modification also reduces noise, vibration and harshness.

During the Five Hundred's developmental stage, Ford paired with Miniature Precision Components, Inc. (MPC), a leading automotive original equipment manufacturer of molded and extruded thermoplastic components, to design and engineer the thermostat housing for the new water pump. The proposed design was complex. It required a plastic part with nine sealing joints to integrate the thermostat housing and water pump, which in turn would allow the part to fit in the small packaging space. On top of the complex design, the part needed to withstand great load force during the assembly line's coolant fill, not to mention prohibit any corrosion as a result of the long-life, chemically aggressive coolant itself.

With these tough design challenges in mind, MPC began researching thermoplastic materials. Known for its dimensional and thermal stability and chemical resistance, Chevron Phillips Chemical Company LP's (Chevron Phillips Chemical) Ryton(R) Polyphenylene Sulfide (PPS) provided the stringent properties necessary to complete the task. Ryton(R) PPS' minimal moisture absorption and low coefficient of linear thermal expansion also made the material an ideal fit for molding to the complex part's tight tolerances. MPC chose to mold a prototype using Ryton(R) PPS R-4-220BL, taking advantage of this grade's hydrolysis resistant properties.

Using Finite Element Analysis, the molded part underwent rigorous structure and stress analysis, several design iterations and mold-filling simulation. Low creep resistance was achieved by conducting a series of strain vs. time curve tests, applying a constant tensile load at constant temperature. Additionally, Ryton(R) PPS' durability enabled the part to withstand a grueling three million cycle fatigue test at 90 psi and 240 F. Ultimately, the part was approved by MPC's Design Validation Plant and integrated into an assembly simulation.

Overcoming space and durability challenges, the teams at Ford, MPC and Chevron Phillips Chemical found a cool thermoplastic solution for a hot innovative design. Today, Ford's Chicago Plant integrates a MPC molded, Ryton(R) PPS direct drive water pump into every Ford Five Hundred that rolls off the assembly line.

About MPC

MPC is a leading automotive original equipment manufacturer of molded and extruded thermoplastic components and assemblies for the major manufacturers. The Company was founded in 1972 when Jay Brost patented one of the first plastic check valves for automotive engines -- and the Company has been an innovator ever since.

MPC has also diversified into medical, recreational, commercial and consumer products. Headquartered in Walworth, Wisconsin, the Company had sales of $167 million in 2004, and has consistently realized a double-digit annual growth rate for more than 10 years. MPC is a privately held company with over 1,600 employees. Sales offices are located in Walworth, Wisconsin, and Southfield, Michigan. Manufacturing plants are located in Wisconsin and Mexico.

For additional information, please visit the MPC website at http://www.mpc-inc.com/ or contact Alexandra Warren at 262-275-5791, ext. 5577 (email: AleWa@MPC-Inc.com).

About Ryton(R) PPS

Ryton(R) PPS and Xtel(R) PPS Alloys are produced worldwide by Chevron Phillips Chemical Company LLC and its affiliates. These engineering plastic materials are known for excellent heat and chemical resistance, as well as its ability to be molded to tight tolerances. Customers use these products in many applications, including electronic components, under-the-hood automotive parts, and appliances.

Since 1972, Chevron Phillips Chemical and its predecessor have led the market in the field of PPS compounds and alloys. The company built the world's first and largest PPS polymer plant in Borger, Texas. Additionally, compounding plants are located in Kallo-Beveren, Belgium; Tuas, Singapore; and La Porte, Texas. In Europe, the Belgium compounding facility is ISO/TS16949:2002 certified (as of April 2004) and is ISO14001:1996 certified (as of March 2001). In La Porte, Texas the Ryton(R) PPS compounding facility is ISO/TS 16949:2002 certified (as of 12/2004). For more information about Ryton(R) PPS, call 1-877-RYTON66 or email Ryton@cpchem.com .

About Chevron Phillips Chemical Company LLC

Chevron Phillips Chemical Company LLC with its affiliates is one of the world's top producers of olefins and polyolefins and a leading supplier of aromatics, alpha olefins, styrenics, specialty chemicals, piping and proprietary plastics. The company has total assets of approximately $7 billion and is owned equally by Chevron Corporation and ConocoPhillips. For more information about Chevron Phillips Chemical, visit http://www.cpchem.com/ .

Inc.