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2007-07-21 News Release

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Weight reduction in automotive applications

Weight reduction is vital in automotive in order to help reduce fuel consumption and emission levels to meet today's and future standards.

One way to reduce weight in a car is to design applications as much as possible in plastics instead of in metal. As metal prices have increased more than the cost of plastics raw materials, this can also lead to further system cost reductions. Other benefits are greater freedom of design, parts intergration and greater corrosion resistance.

DSM Engineering Plastics, one of the world's leading suppliers of engineering thermoplastics, has a long proven track record in metal replacement. Now a further step in value creation is made by developing new applications in plastics. These will be highlighted at the DSM Engineering Plastics booth at K 2007 and include:
• Automotive Engine mounts, Strut mounts, Top Mounts in Stanyl PA46
• Throttle Valve Bodies in Arnite PET
• Structural Reinforcements, Pedestrian Impact Beams, Oil Sumps in Akulon Ultraflow PA6

Stanyl PA46 in metal-rubber applications
Switching from metal to Stanyl PA46 can lead to cost reductions of up to 35% and weight reductions of up to 80% in metal-rubber applications such as automotive engine mounts, top mounts, and exhaust mounts. Other benefits of Stanyl are function integration possibilities and longer lifetime because of no corrosion. Stanyl PA46 is also being used for ETC gears, where the material offers significant weight reduction of up to 50% and greater design freedom versus sintered metals; something which in the end leads to the reduction of valve response times at high frequencies and operating temperatures.

Arnite PET in throttle valve bodies
Electronic throttle controls are used to regulate the air mass flow to the engine. Replacing aluminium with Arnite PET for the throttle valve body yields a range of benefits, including a reduction of the cost per part of 75%, a reduction of the weight of the part by 60%, no icing, increased design freedom and improved fuel efficiency as a result of the supreme surface appearance. Arnite PET is the ideal material for this application because of its unique combination of properties such as high strength & stiffness, good heat resistance and excellent dimensional stability.

Moreover, a special grade Arnite AV2 370 /B may be used for throttle valve bodies with extreme narrow specifications leading to very narrow shot-to-shot and batch-to-batch variations in automotive part dimensions.

Arnitel PB 582-H, a Copolyester Elastomer from DSM, replaced rubber in a recent clean air duct automotive application.

Akulon Ultraflow PA6 for metal replacement applications
Akulon Ultraflow PA6 30-60%GF is excellently suited for metal replacement projects because the material combines excellent flow characteristics with high productivity, and excellent surface appearance - even for 50-60%GF grades - as well as short molding cycles. The material has been approved for Air Bag Containers, which proves that the mechanical performance of Akulon Ultraflow is at least on a par with standard PA6 grades.

Other applications for which Akulon Ultraflow is suited, include structural reinforcements, pedestrian impact beams, oil sumps and pans, pneumatic valve housings and automotive seat adjuster parts. In non-automotive, Akulon Ultraflow is used for furniture, seats, kitchen utensils and garden & lawn equipment.

Read a recent press release about - At K 2007, DSM Engineering Plastics will demonstrate how Stanyl PA46 is the material of choice for the production of a wide range of gears.

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