DuPont Engineering Design magazine (2009/1) by Andrew Wilkins

Engineering Design 2009-01

The quest for sustainable mobility

High performance DuPont materials can contribute to weight reduction, fuel savings and CO2 emission reductions. Read more on pages 2 - 3

The quest for sustainable mobility By Patrick Ferronato, global automotive marketing director at DuPont Engineering Polymers Patrick Ferronato

In dealing with one of the greatest challenges facing the automotive industry, we are working with many of our customers to achieve more sustainable mobility in response to rising fuel costs, regulatory requirements and the need to reduce CO2 emissions. Among the options currently being explored are ways of improving vehicle efficiency by reducing energy loss through friction, the reduction of overall vehicle weight through advanced metal replacement, and the use of new technologies to boost the output of smaller engines. At the same time, automotive manufacturers are introducing more advanced propulsion systems – from hybrids through fuel cells – that can run on various alternative energy sources. Contributing to energy savings today This tremendous challenge has caused us to rethink a number of components and systems, especially in the engine, driveline and fuel systems. The stakes for reducing a vehicle’s carbon footprint and improving fuel economy are high. Several studies show a 25 kilogram (55 lb) weight reduction can yield a 1% increase in fuel economy, depending on the vehicle. A 100 kilogram (220 lb) weight reduction can reduce CO2 emissions by 8.5 grams per kilometer (approximately 0.5 oz per mile). High performance DuPont engineering resins make the replacement of metal

parts and components possible, contributing to weight reduction, fuel savings and CO2 emission reductions. DuPont™ Zytel® nylon resin, for instance, has long been adopted for GM’s 3800 series V6 engine manifold. By replacing metal and reducing weight, this change has saved over 2.6 million barrels of oil from 1992-2006. In a life cycle analysis of the use of virgin glass-reinforced nylon, in place of secondary aluminum, for an engine component of the Ford F250 truck, it was found that the benefits attributable to the reduced vehicle weight far offset energy consumption during manufacture. During the ten year lifetime of 100,000 trucks included in the analysis, a 77 billion BTU (British Thermal Unit) net energy saving was achieved and 11 million pounds (5,000 tons) of CO2 emissions were eliminated. The energy savings could create enough electricity to meet the needs of fortyfour homes for an entire year. In addition, DuPont™ Zytel® nylon resin has contributed to weight savings in a number of system components. As an example, described in further detail in this issue of Engineering Design, the use of Zytel® as an alternative to aluminum for the lower section of an oil pan module from Daimler, helped cut the weight of that component by nearly 50 percent (see also insert on SPE innovation award).

High performance DuPont engineering resins can contribute to weight reduction, fuel savings and CO2 emission reductions: According to Toyota, the V-6 powered 2006 Lexus GS-300 is approximately one percent more fuel efficient – the equivalent of 6 gallons of gasoline per vehicle per year – thanks to the plastic water jacket spacer, made from DuPont™ Zytel® HTN PPA The stakes for reducing energy loss through friction are also high. Studies have shown that approximately 15% of the energy available in gasoline actually gets used to move a vehicle down the road. The remaining 85% of the energy is lost to engine and driveline inefficiencies, accessories and idling. To help the automotive industry improve efficiency and get more power to the wheel, DuPont has created the “Science of Friction” program to put the science of DuPont materials – from DuPont™ Vespel® parts and shapes to DuPont™ Teflon® – to work and reduce friction, especially in driveline systems. For example, Vespel® demonstrates a 30% to 40% reduction in friction when used in fork pads, which are used to engage gear sets in manual transmissions. Similarly, the use of Vespel® in automatic transmissions can

Significant breakthroughs in sustainability honored Two breakthroughs in automotive sustainability, featuring high performance polymers from DuPont, were recently honored by The Society of Plastics Engineers (SPE) Automotive Division. An oil pan for Daimler’s new 4-cylinder diesel engine (OM651), the first worldwide to consist of a polymer module (made of DuPont™ Zytel® nylon – see pages 4&5), took top honors in the powertrain/chassis category (Daimler representatives Dr. Günther B. Zoll (left), specialist supervisor plastic engine components, and Nuri Tiraki, project development engineer for the OM 651, are pictured with the module and award). Meanwhile Ford was named finalist in the powertrain/chassis category for an innovative “capless” fuel filler system which uses DuPont™ Zytel® HTN PPA. The new system is compatible with biofuels and supports the compliance of Ford’s vehicles to all California Low Emission Vehicle (LEV II or PZEV) requirements.

Engineering Design 2009-01

improve the torque loss of seal rings by up to 50%. Additionally, automotive manufacturers can increase loads on thrust washers twofold, encouraging further metal replacement for weight and space savings. Energy savings for the future Looking to the future, and with a new generation of propulsion systems in mind, DuPont is also leading the development of safer, more efficient energy storage options for a variety of consumer and industrial applications, including electric/hybrid vehicles. Our focus is on creating energy storage options that result in less wasted energy and heat gain due to low resistance, longer device life from less heat and higher performance materials (chemical and thermal stability), higher

energy output due to a thinner separator (resulting in more active materials in the same space) and processing cost savings, due to higher temperature stability and less water absorption. Key DuPont products in development for the energy storage sector include: DuPont Hybrid Membrane Technology for battery separators; engineering polymers such as Zytel® nylon for battery pack housings, sealants and connectors; fluoropolymer resins for capacitors and lithium ion batteries; and DuPont Teijin Films separators for dry capacitors. For instance, DuPont is developing a battery separator for electric/hybrid vehicles which will enable higher operating temperatures in use, more power generation and lower ionic resistance for increased battery output. In device testing to date, DuPont

has seen up to a 40% improvement in the life of the device with properly designed energy storage components, such as super-capacitors. Our Hybrid Membrane Technology has shown significant advantages in high power applications - in devices it will deliver up to 50% more energy at high discharge rates. Meanwhile, our higher temperature materials have enabled the reduction of production times and broadened device application temperature capabilities. The results of this smarter engineering? The potential for increased power density and less wasted energy and heat gain; increased energy supply and the enabling of smaller devices; higher process temperatures, resulting in reduced manufacturing costs and improved device life and effective barriers to address safety issues.

This issue in brief Page 4

Page 10 First polymer oil pan module for use in serialproduction cars

Meeting a “baffling” design challenge An integrated baffle and seal lip assembly, made of Hytrel®, is used in two new transmissions from General Motors.

A joint development between Daimler, Bruss and DuPont saves manufacturing cost as well as weight.

Page 6

Pages 11 & 12 New wheel safety technology

News Crastin® and DuPont dye-sublimation tech-

VisiLok, a patented system featuring a housing made of robust Zytel® HTN, provides an effective solution to the risk of wheel detachment

nology used for limited-edition champagne bottles; DuPont extends its MetaFuse™ alliance; New Delrin® 300CP for enhanced cost-efficiency

Page 7

Page 13 Extending new processing technologies

Promoting safer oven use

Material and technical support from DuPont has enabled Turkish automotive supplier Teklas to produce 3D blow-molded parts.

The ‘Impulse’ guide for Fagor ovens, mounted on a support made of Zenite® and metal, enables safe and easy access to cooked food.

Page 8

Page 14 A new track for Zytel®

Smooth operator

A new railway fastening system is one of the first to use a base plate made of Zytel® nylon as an alternative to steel.

Patented ball transfer units, made using DuPont™ Vespel® parts and shapes, are used for the smooth and efficient handling of flat panel displays and solar panels.

Engineering Design 2009-01

First polymer oil pan module for use in serial-production cars by Dirk Winnemann, DuPont Engineering Polymers, Germany

Oil pans for cars were one of the last great strongholds of metal. Now, for the first time, an oil pan module made of polymer has gone into serial production. The joint development, between Daimler, the supplier Bruss and DuPont, saves manufacturing cost as well as weight, and – in the long term – offers the potential for greater functional integration. To date, thermoplastics have successfully replaced metal in applications such as air intake manifolds, slide and tensioning rails, cylinder head covers and, most recently, oil filter modules. Now, with the first oil pan module to be made of a thermoplastic polymer for serialproduction cars, Daimler has broken new ground. Since the end of 2008, it is part of the new 4 cylinder diesel engine (model OM651), used initially in cars belonging to the C Class range. Various additional ranges are set to follow.

A complex set of requirements Vehicle oil pans are exposed to a combination of stresses as a result of lubricant-use, temperature changes and static and dynamic loads. Even so, their seal performance must be maintained in all conditions. Additionally, the pan is required to withstand the rough handling by a forklift truck of the combined engine and gearbox unit. Its specifications are correspondingly diverse and complex. It was for this reason that the development team

decided from the outset to use DuPont™ Zytel® 70G35 HSLR A4, a glass-fiber reinforced, heat-stabilized and hydrolysis-resistant grade of nylon 66, which is tried and trusted for engine components. Its high melt flow enables long flow distances, short injection times and the molding of thin partition walls and ribbing. Integrated oil deflector as reinforcement Fundamental to the design of the oil pan was the need to achieve sufficient stiffness within the flat section ahead

Zytel® 70G35 HSLR A4

High flow Easy to weld Stiff and dimensionally stable Hydrolysis-, temperature- and chemical resistant

Engineering Design 2009-01

Simulations of structure-borne noise, carried out by DuPont, were carried out with partially-filled oil pans. of the oil sump, thereby minimizing sealing area deformation. The adoption of any internal ribbing should not interrupt oil flow, while the use of external, reinforcement ribbing was almost impossible due to the lack of available space. The solution was to create a sandwich design with two injection-molded parts. A separately-produced oil deflector is welded onto the flat section of the pan, and is used to calm the oil churned by the crankshaft and balance shaft, and direct it back into the oil pan. Moreover, the deflector significantly improves the vibration behavior of the overall design. The high reinforcement ribbing in the sump simultaneously acts as a baffle, also helping to calm the oil. A die-cast aluminum upper shell is used to attach the oil pan to the engine block. The overall construction achieves a significant weight reduction of 1.1 kg compared to an entirely aluminum design. Simulation shortens development time Before producing the first tool, Bruss requested technical support from DuPont in addition to its own, compre-

hensive simulation software. Finite element analysis (FEA) was used to refine the positioning of the ribbing at the edge of the pan, thereby contributing significantly to the overall stiffness of the critical flat section despite its minimal height. Flow studies, also based on FEA modeling, were used by DuPont to gauge and optimize the impact of wall thickness, the number of gates, and their positioning, on weld line formation and warpage behavior. Indeed, due to the high melt flow of Zytel® 70G35 HSLR A4, a single, central gate was enough to completely fill the mould cavity, while permitting short molding cycles. Finally, at the DuPont European Technical Centre in Geneva, the structure’s properties were further analyzed by simulating the combined engine and gearbox unit being dropped heavily by a fork-lift truck. This allowed critical parts – particularly the external ribbing designated for the contact area – to be identified and dealt with. Real-life testing of prototype parts at Bruss confirmed the success of the simulated design – even after 1000 hours of aging in hot oil at 150 °C (302 °F) The C-Class from Mercedes-Benz has rearwheel drive and the engine is installed lengthwise. As a result, the oil pan is partially situated above the cross beam of the front axle. This requires this section to be kept very flat. The part behind it – in terms of direction of travel – forms the considerably deeper oil sump, with a capacity for approximately 6 liters of motor oil.

Engineering Design 2009-01

Welding of the oil deflector to the oil pan module was optimized by a team comprising Bruss, DuPont and the joining product manufacturer, Branson. All tolerances were defined with regard to process control and the material used, in order to ensure reliable joints, even in unfavorable conditions. Subsequent pull-off tests revealed pull-off forces of around 1300 N, a higher value than required. In its current form, the component meets all requirements. The seal area remains leak free during hot oil testing at 150 °C, at minimum sealing force (smallest seal in largest groove) and during alternating climate testing. Wide scope for integration Increased integration means lower manufacturing costs. In its current form, and as described in this article, an oil deflector has already been integrated. Additional functions, envisaged for integration in future oil pan models, could include the oil pick-up pipe, oil level switch, oil filter and other oil return components or oil pumps.

Contact Daimler AG, Mercedes-Benz Cars 70546 Stuttgart, Germany Dr. Günther B. Zoll Tel. +49 711 17 20 235 Fax +49 711 17 790 20 235 guenther.zoll@daimler.com Dichtungstechnik G.BRUSS GmbH & Co KG 22955 Hoisdorf, Germany Dr.-Ing. Roland Kral Tel. +49 4107 59 386 Fax +49 4107 378 72 08 kral@bruss.de

New wheel safety technology By Rob Coates, DuPont Engineering Polymers, UK

Each year thousands of commercial transport and heavy goods vehicle operators are faced with the risk of sudden and often unexplained wheel fixing defects or detachment. A patented system from the UK company VisiLok Limited, and featuring a housing made of robust DuPont™ Zytel® HTN, provides an effective solution which addresses nut relaxation the instant it occurs and flags the operator into action.

Wheel nut relaxation is a serious and recognized global issue in the commercial transport industry. The typical annual frequency in the UK of wheel fixing defects is between 7,500 and 11,000, resulting in between 150 and 400 wheel detachments. Although the exact cause of wheel nut relaxation and losses is not yet known, it is clear that if not managed correctly, operators and management teams around the world could face severe penalties and even prosecution. The VisiLok road wheel safety nut is the culmination of four years of research and development, testing and trials, which addresses both the need for nut retention and relaxation indication. It consists of a steel nut incorporating a spring-driven lock and flag mechanism (housed in a 50% glass-

reinforced grade of Zytel® HTN PPA) and a modified, slotted stud. In the event of clamping force being lost, the nut starts to rotate. At this point the VisiLok system arrests further rotation in order to prevent the nut spinning off. At the same time, highly visible, yellow flags are displayed to alert the operator that the wheel requires attention. While achieving the dual function of arresting the movement and flagging the problem, VisiLok behaves in all other respects as a standard road wheel nut. No special tools are required and there is no time loss in fitting or removing a VisiLok nut. Reasons for the selection of the particular grade of Zytel® HTN, 53G50, for the housing of the lock and flag mechanism were numerous. The polymer’s high stiffness prevents deforma-

tion of the housing during use, while its dimensional stability is fundamental to the long-term, reliable operation of the safety device. Moreover, despite being partially embedded within the steel nut, the upper section of the housing is exposed to road conditions, requiring the polymer to be resistant to chemicals such as road salts, oil and fuel, as well as forceful impacts. “After going through a number of development stages which included proving the basic integrity of the design concept and function, we needed to ensure that the VisiLok nut and stud was robust in all operating conditions, in which respect the adoption of Zytel® HTN for the housing of the safety mechanism was key,” explains Barry McGowan, managing director of VisiLok Limited (pictured left with the VisiLok nut). “We selected the component material combinations carefully to prevent corrosion from jamming the mechanism, while keeping the component count to a minimum, and ultimately produce a costeffective, universally applicable solution which would put an end to the wheel loss problem once and for all.”

DuPont™ Zytel® HTN High stiffness and dimensional stability Impact resistance Chemical resistance

Contact VisiLok Limited Henfaes Lane Welshpool, SY21 7BJ Tel +44 1938 553380 sales@visilok.com www.visilok.com

Engineering Design 2009-01

Extending new processing technologies By Hasan Camur, DuPont Engineering Polymers, Turkey

Seeking to extend its processing capabilities, the Turkish automotive supplier Teklas chose DuPont as its development partner for the production of 3D blow-molded parts on the basis of its high performance DuPont™ Zytel® nylon and first class technical support. The majority of the 37-year history of Teklas Kaucuk Sanayi ve Ticaret A.S (Gebze, Turkey) has been as a producer of rubber-based parts for the automotive industry. The broad range of products produced at its Turkish and Bulgarian facilities include turbocharger hoses, cooling hoses, brake hoses, fuel lines, windshield wipers and anti-vibration parts. Yet, it was the realization of the value to be gained by Teklas and its customers from the production of blow-molded air ducts using thermoplastics, that led to the company turning to DuPont for the material and development support required to engage in the technically-challenging process of three-dimensional (3D) blow molding. 3D blow molding is an established approach for demanding duct and fuelsystem parts. The process allows laying extruded parisons into special molds using robotic manipulation and suction. These 3D techniques produce contoured parts that are virtually flash-free, with a minimum of pinch-off points or knit lines on the finished part, to improve mechanical performance in critical stressed areas. DuPont has installed 3D

Engineering Design 2009-01

Cooperation between DuPont and Teklas resulted in the successful blow molding of the intercooler air duct for Seat: (left to right) Yavuz Tugyan (technical manager at DuPont Turkey), Murat Bozkurtlu (business development manager at Teklas), Hasan Camur (sales & marketing manager, DuPont Turkey), Adem Senemtası (executive technician, Teklas) and Nedim Us (executive production leader, Teklas) blow molding equipment at its European Technical Center (ETC) in Geneva, Switzerland, for use with its modified engineering thermoplatics for advanced blow molding. Following the signing of a development agreement between the two companies, technical representatives of Teklas visited the ETC in 2006. Teklas took delivery of its first 3D blow molding machine at the start of 2007, and immediately set about the development of an intercooler air duct for Seat – a complex challenge, even for those with more experience of the processing technique. Indeed, Teklas was at first so unsure of its ability to produce the complex part using a single tool, that its initial plan was to mold the duct in two parts and to subsequently weld them together. However, with DuPont’s support, Teklas succeeded in producing a single part made of DuPont™ Zytel® BM73G15THS, a 15% glass-fiber reinforced, heat stabilized, lubricated and toughened polyamide 6 for blow molding. Specific application requirements for the material included resistance to temperatures of around 155 °C (355 °F) and 1.9 bar air pressure. The duct and the material have since

been approved by Seat. “Over the course of the last 18 months we have learnt a lot about 3D blow molding, and currently have several air duct projects in development with OEMs,” comments Murat Bozkurtlu, business development manager at Teklas. “Our success in this area is primarily due to the partner-like approach of DuPont to extending our knowledge of this relatively new processing technology, as well as the quality of its materials.”

DuPont™ Zytel® nylon Blow-molding grade Mechanical performance Temperature resistance

Contact Teklas Kaucuk Sanayi ve Ticaret A.S Baris Mah. Kosuyolu Cad. No: 94 41400 Gebze / Kocaeli Tel. +90 (262) 648 44 00 Fax +90 (262) 641 79 63 www.teklas.com.tr

A new track for Zytel® By Josep Ros and Jaume Ventayol , DuPont Engineering Polymers, Spain

Mondragón Soluciones, of Valencia, Spain, has been a manufacturer of railway fastenings for more than fifteen years, with a reputation for innovative products. None more so than its latest fastening product, which is one of the first to feature a base plate made of DuPont™ Zytel® nylon, chosen for its elasticity and strength, as a lightweight and robust alternative to steel. Railway fastenings fulfill a number of functions. Beyond their obvious tasks of keeping the rail attached to the sleeper and maintaining the longitudinal direction, gauge and inclination of the rails, one of their principal roles is to spread, absorb and transmit the dynamic loads from the wheels of the moving train to the sleeper and track bed. It was in relation to performance in this key area that Mondragón Soluciones, a Spanish company with more than 50 years of experience in producing injection-molded parts for telecommunications and railroad industries, sought an alternative to the steel base

The railway fastening system from Mondragón Soluciones is one of the first to feature a black base plate made of DuPont™ Zytel® nylon, secured by metal tension clamps (in green)

plates commonly used in railway fastenings around the world. “We wanted to replace steel with nylon in this extremely critical application – which takes the full impact of the train wheel – in order to gain performance benefits that were previously unobtainable due to the rigidity of steel,” explains Juan Vives Clavel, director of R&D at Mondragón Soluciones. “We chose a 35% glass-fiber reinforced grade of DuPont™ Zytel® as the replacement material – a nylon resin we were already familiar with in terms of its high dimensional stability and ease of processing.”

A range of benefits Initial trials and prototype testing of base plates molded from Zytel® 70G35HSL demonstrated that the material possesses not only a high modulus of elasticity, required to withstand the impact of train wheels, but also sufficient elongation at break. As a result, the nylon plate is capable of absorbing energy generated by the passing train, thereby reducing the impact and vibration forces responsible for track deterioration. The dielectric strength of the material, necessary to electrically-isolate the tracks from the ground and from each other, also far exceeded cus-

Engineering Design 2009-01

welcomed the new product, which is transported manually to each sleeper, as it is approximately a sixth of the weight of its steel equivalent.

Familiar with the processing of Zytel® from previous projects, Mondragón Soluciones avoided sink marks at the intersection of the ribbing and the walls by optimizing the ribbing’s thickness tomers’ requirements. “To further ensure that both the design and the material met all our customers’ expectations, we conducted additional tests which enabled us to confidently predict that the base plate molded from Zytel® would retain its mechanical properties in the long-term. This is due, in large part, to the nylon’s high chemical resistance to products such as oils,

DuPont™ Zytel® nylon Strength and elasticity Dielectric strength Chemical resistance

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greases and herbicides that are occasionally used during track maintenance,” adds Juan Vives Clavel. Familiar with the injection-molding of Zytel® from previous developments, the processing of the nylon base plates presented few problems to the technicians at Mondragón Soluciones. Demolding was facilitated by the use of a small draft angle, despite the part’s high wall thickness, while sink marks at the intersection of the ribbing and the walls of the molded part were avoided by optimizing the ribbing’s thickness. “As with previous projects, the support and advice that DuPont provides has given us additional confidence in our choice of material, and we value it highly,” adds Juan Vives Clavel. Further confirmation of Zytel® nylon resin as a suitable alternative to steel for the application soon followed. The Mondragón Soluciones’ design has since been certified as conforming to the Spanish standard UNEEN 13164 by the Laboratory of Science and Engineering Materials department and the University of Cantabria. Those handling material on-site have also

A perfect partner: Hytrel® rail pads Similar to other suppliers of railway fastenings from around the world (see ED 2006-1), Mondragón Soluciones uses rail pads made of DuPont™ Hytrel® thermoplastic polyester elastomer in its own systems (colored light gray in exploded view, left of page). The pads complement the base plates made of Zytel® in terms of their performance, providing the ideal combination of flexibility and durability required to perform under high load over an extended period. The chemical resistance of Hytrel® was a further key requirement. The new fastenings were first installed on a suburban metro line in Mexico City during the first half of 2008, and most recently for a tram system in Blankenberger, Belgium. “Our experience to date has confirmed our decision to develop this new type of polymer product. It combines the required strength for the application with the right elasticity, which is essential when seeking to reduce impact and vibrations in the track structure. In fact I would go as far as to say that it has destroyed the myth that steel must be used for this type of rail fastening,” concludes Juan Vives Clavel.

Contact Mondragón Soluciones Pol. Ind. El Mediterráneo c/ La Fila núm. 5 46550 Albuixech, Valencia, Spain Tel. +34 961 415 400 www.mondragonsoluciones.com

Meeting a “baffling” design challenge By Dino Tres, DuPont Automotive development programs manager Polymers, US

An integrated baffle and seal lip assembly, made of DuPont™ Hytrel® thermoplastic polyester elastomer, is used in two new transmissions from General Motors. The unique solution helps condense packaging space and enable better clutch and transmission durability. General Motors’ new 6T40 and 6T45 transversely mounted 6-speed automatic transmissions deliver power to a wide range of vehicles available globally from GM, including the 2008 Chevrolet Malibu, Daewoo Tosca and Buick LaCrosse for the Chinese market. Located in the torque transfer case of each of these transmissions is an integrated baffle and seal lip assembly, made of Hytrel®, which is designed to reduce oil aeration, provide a seal that limits fluid from flooding the chain, while ultimately enabling transmission fluid fill for life. The one-piece, flexible component significantly reduces overall cost because it avoids the use of costly multi-step production and assembly processes, which were typically metal stampings or plastic carriers with a rubber bead.

The close cooperation between DuPont and GM on this project started a couple of years ago, when they sought to optimize the material and process for the design. In turn, this would allow GM to cost-effectively realize the full benefits of the innovation. Indeed, the eventual selection of Hytrel® was key to the design’s success. Even though it’s not typically considered for transmission applications, it proved to offer the right balance of flexibility and stiffness despite temperature extremes to fit the complex geometries of the transfer case, while resisting swell when exposed to oils, aliphatics and aromatic solvents. Two years of development saw tooling iterations and material upgrades to optimize performance for service temperatures that cycle between -40°C

(-40°F) to +140°C (284°F). The team extensively used the Troy-based DuPont Automotive Application Development Center to test materials, various processes and tools. Now in production, the part is manufactured by Chunil Engineering in Korea and CWB Group in China. “The success of this design on the 6T40 program was followed quickly by application of this design on the 6T45 program, which recently went into production,” said Jatin Desai, General Motors Powertrain transmission structural component global team leader. “This generation offers improved performance, yet still packages the 6speed into the space of a 4-speed.”

Engineering Design 2009-01

Picture perfect

The champagne bottle for the Taittinger Brut Millésimé 2000 – Rauschenberg Collection, is encased in a molded “shell” of DuPont™ Crastin® PBT, and decorated using DuPont dye-sublimation technology – selected for its ability to accurately reproduce delicate artwork on complex shapes. The Taittinger Collection is a series of limited-edition champagne bottles (of around 5,000 units), created between 1983 and 2007, featuring the work of artists from around the world on their shells. The most recent of the eleven artists to be featured in this series is the American painter Robert Rauschenberg, well-known for his “Combine” works that integrate the aspects of painting and sculpture. “The artwork created by Rauschenberg for our 11th edition makes use of a largely chromatic, but very subtle, palette of colors, with very light and “faded-looking” tones of mauve, brown and yellow, together with large areas of dark grey and black,” explains Dominique Garreta, marketing director at Taittinger. “Three-dimensional sublimation printing was the most effective way of reproducing these very delicate colors on such a complex shape, thereby requiring a material for the shell that would resist the temperatures incurred during the sublimation process.” This ruled out ABS, the polymer initially foreseen for the application and used in previous ranges, while subsequent testing demonstrated Crastin® to provide the best combination of temperature resistance, colour reproduction and post-shrinkage. The dye sublimation technology was developed by DuPont in partnership with Pacific Colour, of Lons-le-Saunier, France. http://www.taittinger.com/la-taittinger-collection.html

DuPont extends MetaFuse™ alliance DuPont has announced a long-term alliance with Californiabased PowerMetal Technologies, Inc. to further develop and commercialize MetaFuse™ nanocrystalline metal/polymer hybrid technology, with initial development programs targeted at electronic hand-held devices, sporting goods, furniture, power tools and appliances. A similar alliance, to bring this technology to the automotive market, was signed with Morph Technologies a year ago. Under the agreement, DuPont will provide proprietary resin formulation and application development leadership to global customers to bring this innovative technology to market. PowerMetal will apply its nanotechnology expertise to the manufacture of extremely lightweight components with the strength and stiffness of metal combined with the design flexibility and lightweight benefits of DuPont Engineering Polymers high-performance thermoplastics. Other terms and conditions were not disclosed. MetaFuse™ nanometal/polymer hybrids can be used to manufacture extremely lightweight components with the strength and stiffness of metal combined with the design flexibility and lightweight benefits of high-performance thermoplastics. The technology employs a proprietary process that precisely applies ultra high-strength nanometal to components made of DuPont engineering polymers to create lightweight components in myriad, complex shapes with the stiffness of magnesium or aluminum and higher strength. http://plastics.dupont.com

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MetaFuse™ nanometal/polymer hybrid technology has been developed by DuPont Engineering Polymers, Morph technologies Inc., Integran Technologies Inc. And PowerMeta™ Technologies.

DuPont™ Delrin® 300CP optimises impact performance, flow and costefficiency New DuPont™ Delrin® 300CP combines high impact resistance, even at low temperatures, with high stiffness, strength and elongation at yield – yet it is particularly efficient during processing, thanks to its relatively low melt viscosity. The cost of the new resin is around that of standard polymer grades, allowing for more cost-efficient solutions. The broad range of potential applications includes automotive components, sports and leisure products as well as mass-produced articles. from 13 kJ/m2 to 8 kJ/m2 with a high impact-resistant copolymer). Its high elongation at yield and simultaneously high stiffness and creep resistance help extend its application in the design of continuously-loaded, springelastic components. Delrin® 300CP presents greater design flexibility and freedom by combining high melt-flow with mechanical performance at levels that were, to date, only possible with polyacetals of considerably higher viscosity. This enables the reduction of wall thicknesses and material usage while maintaining load capac-

Designers have typically had to make compromises when balancing moldability, mechanical performance and low temperature toughness in acetal parts. New Delrin® 300CP now provides an almost universal solution. The material demonstrates consistent impact performance over a broad temperature range. For example, its notched Charpy impact strength of 10.5 kJ/m2 at room temperature, only falls to 10 kJ/m2 at -30 °C (-22 °F), whereas other, specially impact-modified copolymers experience substantial falls in this value at such temperatures (e.g.

ity, the design of more complex components, or – at the same wall thickness – the use of longer flow distances. At the same time, the low viscosity of the melt improves weld line strength, thereby facilitating tool optimization, e.g. the use of several injection gates as well as shorter cycle times. Thanks to its high heat deflection temperature, Delrin® 300CP can be used at considerably higher temperatures than comparable copolymers. The material does not need to be pre-dried, which is of additional benefit to the processor. As is typical for all Delrin® polyacetals, the new grade 300CP provides high surface hardness, very low wear and friction, resiliency and a high resistance to chemicals and solvents. Potential applications include automotive components (such as fasteners, seatbelt components, levers, brackets, gears and switches), buckles, latches or surface parts for sporting goods, hardware for windows and doors, parts for domestic and commercial irrigation systems, as well as general components for snap-in joints.

Notched Charpy -30°C

Yie ld St re ss 12

80 60 40 20

us odul ile M Tens

Mel t Flo w Ra te

100

DuPont™ Delrin® 300CP High impact-modified copolymer High viscosity copolymer

n rai t S ld e i Y Engineering Design 2009-01

Promoting safer oven use By Elisenda Falcó and Oscar Gaona, DuPont Engineering Polymers, Spain

The ‘Impulse’ guide for Fagor ovens, a system patented by Spanish company Fagor Electrodomésticos, is a totally new device for oven cooking: by simply pulling open the oven door, the hot oven tray automatically slides out for safe and easy access. The guide is mounted on a support made of DuPont™ Zenite® and metal. The new ’Impulse’ system to access hot oven trays in ovens from Fagor Electrodomésticos (Basauri, Spain) has been developed and patented by the company with the support of Hettich International. It includes selfextracting Quadro runners, which allow total access to food without touching the oven tray. By simply opening the oven door, the tray automatically glides forward with the food – when the door is closed, the tray slides back in. The operation of this application relies on gravitational

DuPont™ Zenite® LCP Temperature resistance Food-contact approved Surface finish

Contact Fagor Electrodomésticos Urtzi Zubiate Innovation Leader – Ovens Business Avda Cervantes, 45 48970 Basauri (Bizkaia) , Spain Tel.: +34 943 038 213 uzubiate@fagorelectrodomesticos.com www.fagorelectrodomesticos.com

Engineering Design 2009-01

force in order for the Quadro runners, mounted on stainless steel ball bearings, to glide out in a lineal movement. In order to achieve this, Fagor Electrodomésticos worked with Hettich International, a supplier of runner systems, whose Spanish subsidiary, OBE Hettich S.L., is based in Aizarnazábal (Guipúzcoa, Spain). The runners have an end-cap made of Zenite® liquid crystal polymer resin. The material, already widely used in the electronic industry, was selected for this application due to its benefits in cooking. The particular grade of Zenite®, FG7145L BK011, is resistant to high temperatures, is approved for use in repeated food-contact applications, delivers high performance and an appealing surface finish. “We were looking for a material for the end-caps that could withstand the high temperatures encountered in domestic ovens, which can be as high as 240 °C (464 °F). Moreover, the parts were required to support the weight of the oven tray plus food, at simple compression and supported by a stainless steel guide, but this was no great challenge”, explains Urtzi Zubiate, innovation leader at Fagor Electrodomésticos. “The sole mechanical stress the endcaps encounter is the impact against the oven’s door. The material needed to

be of sufficient strength to withstand the initial impact until the tray begins to glide back, yet it shouldn’t be as hard as metal, so as to avoid scratching the glass door. That’s how we arrived at engineering thermoplastics providing the best possible solution.” Further unexpected benefits were gained through the adoption of Zenite®. These included the opportunity to achieve an impressive part thickness of 13 mm (0.5 inches) for a part which is 80 mm (3 inches) long, as well as the ability to assemble the stainless steel and plastic parts, without the need for additional components, for further cost savings. Indeed, with regard to cost, the reduced cost of tooling for the Zenite® part makes it the most cost-effective alternative. Fitting with the Quadro guide is ideal, due to the high dimensional stability of the end-cap’s neck, and the elimination of additional production steps – all of which will help make Zenite® the material of choice for applications in other oven ranges in the future.

Smooth operator By Masayuki Yonezawa, DuPont Engineering Polymers, Japan

Patented ball transfer units, made using DuPont™ Vespel® parts and shapes, are used for flat panel display and solar panel handling. Combining low abrasion and low particle generation, the ball transfer units from ISB (Iguchi Kiko Co., Ltd.) enable smooth and efficient operation in cleanroom conditions. Ball tables are industrial conveyors that use fixed balls to transport products and materials by rolling instead of using a moving belt or chain. The ball tables are made up from multiple ball transfer units, each consisting of a large, load-bearing ball which sits atop smaller balls inside a semispherical main body. Both ball tables and ball transfer units are designed for industrial and commercial applications that require the transportation of bulk materials, boxes, packages, or parts in a predetermined path, and that have fixed or selective points for loading and

discharging. The components of the ball transfer units are usually made of steel, carbon steel, or stainless steel. It was when considering the development of ball transfer units for the alignment of flat panel displays and solar panels, that Japanese company ISB (Iguchi Kiko Co., Ltd. Tokyo), a supplier of quality ball bearing systems, discovered the requirement for a tailormade solution for use in cleanroom environments. “Conventionally, solid pins are used to support the glass alignment process, which generate particles and result in high friction due to

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Comparison of Coefficient of Friction between PEEK Pin and ISB Ball Transfer

repeated, abrasive motion. There was a strong need to improve the process,” explains Hiroshi Kawai, marketing department director at ISB. “But nobody believed that ball transfer units would solve the problem because of the number of metal parts moving within them, which was seen as the source of contamination by cleanroom process engineers,” The solution lay in the adoption of different families of Vespel® parts for components in ISB’s ISC range of ball transfer units for cleanroom applications. Due to the high surface hardness and dimensional stability of the Vespel® parts – including the main body, small balls and large ball – their elastic deformation, caused by the weight of the transported material, can be controlled. Similarly, the high thermal deformation temperature of the Vespel® parts (above 300 °C or 572 °F) also helps limit deformation. Consequently, frictional resistance to movement of the transported material is minimized, allowing it to be moved both smoothly and accurately by a

Engineering Design 2009-01

small external force. The elimination of metal components from the ball transfer units helps remove the source of foreign matter (e.g. metal powder resulting from abrasion) which can potentially damage the delicate panels. The excellent erosion resistance of the Vespel® parts prevents the depositing of chemical substances, further reducing the risk of contamination. Excellent resistance to UV light or chemical resistance are additional benefits, as Hiroshi Kawai confirms: “By selecting Vespel® as the key material for our ISC range of ball transfer units, we have obtained particularly good results when using the units in pretreatment devices for a liquid-crystal panel substrate glass, such as a vacuum chamber, or a heating oven.” Over a six-year period, DuPont in Japan worked with ISB on selecting the best material and technical solution to meet the needs of flat panel display and solar panel manufacturers. A range of Vespel® series are used in the ISC ball transfer units, including those from the Vespel® TP-8000 family of finished parts and shapes, whose high purity and resistance to plasma and heat makes them well suited for uses within the semiconductor industry. The material is weldable and wear resistant and maintains its good dielectric properties even at permanent operating tempera-

Engineering Design 2009-01

tures of up to 200 °C (392 °F). Other Vespel® series used include Vespel® SP-202, which decreases electrostatic loading in the manufacturing and handling of flat glass panels for liquid crystal displays and is ideal for use with products that are handled in high-temperature, vacuums or reactive environments. Vespel® SCP-5000, whose benefits include ultra-high purity and high stiffness, and Vespel® SP-1, delivering exceptional wear resistance, insulation, and a low coefficient of friction, complete the list of DuPont materials used. “The proven performance of Vespel® parts and shapes in highly demanding semiconductor applications, in terms of their purity, wear resistance and wide range of thermal resistance, was one principal reason to work with DuPont,” explains Kaoru Iguchi, president of Iguchi Kiko (ISB). “The other is the strong emphasis on development support for the material and testing. With the cooperation of DuPont, we were able to accelerate development faster than ever before.” According to Iguchi, flat panel display and photovoltaic manufacturing engineers have boosted their productivity by using the ISC range of ball transfer– indeed their application has extended from flat panel display and photovoltaic manufacture in Asia to parts of North America. In 2005, Nikkan

Contact Iguchin Kiko Co., Ltd. (ISB) 1-20-7, Minamiohizumi Nerima-ku Tokyo 178-0064,Japan Tel. 03-3923-1211 Fax 03-3923-8100 http://www.isb-iguchi.com/

DuPont™ Vespel® parts and shapes Wear resistance Temperature resistance High purity

Kogyo Newspaper awarded the ‘ISC Ball Transfer for Cleanrooms’ with the “Japanese Brand Award” for its innovative solution in flat panel manufacturing. In 2007 ISB & DuPont’s joint patent for the ball transfer unit and ball table was granted in the U.S. “With DuPont as a key development partner, we will continue to develop new products, new applications, and new markets,” concludes Kaoru Iguchi.

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parts and shapes

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high performance polyester

thermoplastic rubber that resists oil & heat

ASIA-PACIFIC Ukraine Du Pont de Nemours International S.A. Representative Office 3, Glazunova Street Kyiv 252042 Tel. +380 44 294 96 33 / 269 13 02 Fax +380 44 269 11 81

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The DuPont Oval Logo, DuPont™, The miracles of science™, and Crastin®, Delrin®, DuPont™ ETPV, Hytrel®, Minlon®, Rynite®,Thermx®, Tynex®, Vespel®, Zytel®, Zenite® are registered trademarks or trademarks of E.I. du Pont de Nemours and Company or its affiliates.

Publisher:

Evelyne Schütz DuPont Engineering Polymers 2, ch. du Pavillon CH-1218 Le Grand-Saconnex Geneva Switzerland Tel.: +41 22 717 51 11 Fax: +41 22 580 22 35

Editor:

Andrew Wilkins PR andrew.wilkins@btconnect.com

Layout:

Konsens PR GmbH & Co. KG mail@konsens.de

Engineering Design is published in English, French, German, Italian, Spanish and Russian by Du Pont de Nemours International S.A. P.O.Box 50, CH-1218 Le Grand-Saconnex Geneva,Switzerland. The information set forth herein is furnished free of charge and is based on technical data that DuPont believes to be reliable. It is intended for use by persons having technical skill at their own discretion and risk. DuPont makes no warranties, express or implied, and assumes no liability in connection with any use of this information. © 2009 E.I. du Pont de Nemours and Company Printed in Switzerland L-14335-00