2004 Dodge Durango SUV

TROY, Mich., USA -- September 18, 2004 -- Jobwerx News -- DuPont identifies a new resin for the use of plastic as a reinforcement for body panels. The bracket mirror part is molded and supplied to the Chrysler Group for the second-generation 2004 Dodge Durango SUV and Dakota pickup by Mayco Plastics, Sterling Heights, Michigan.

Chrysler Group engineers wanted to reduce the expense and complexity involved in using a support bracket that was stamped and welded together in multiple steps from steel, then coated for corrosion resistance. The bracket, located between the inner and outer door panels, supports the driver- and passenger-side exterior mirrors.

Together, DuPont and Chrysler, identified DuPont™ Rynite® PET as the prime candidate 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 result – a mirror housing bracket that 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 new part simply snaps in place quickly and accurately during assembly, assuring it will stay in place until the mirror is bolted on. It also weighs 86 percent less than the equivalent part in steel.

"The weight, cost and EHPV savings alone make this a breakthrough application," a Chrysler Group truck products engineer stated. "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."

Rynite® has been recognized as a plastics material combination of structural strength, stiffness, dimensional stability and extreme heat resistance with no warp.

Structural strength is vital in supporting the oversize side mirrors appropriate to a large sport utility or pickup. Any flex in this crucial part of the door would show up as annoying vibrating images in the mirror.

Rynite® resist weather and harsh chemicals and doesn't absorb moisture. It won't warp even when exposed to water infiltration. Rynite® thermoplastic polyester resin unites the best properties of reinforced polyethylene terephthalate (PET) with easier moldability.

And, because of its low water absorption, parts in Rynite® PET maintain their properties and dimensional stability. This makes it a prime candidate for the replacement of die-cast metals and thermosets in many demanding applications where stiffness, critical tolerances and exterior finish are key requirements. The outstanding flow characteristics of Rynite® PET allow it to fill complex, thin-walled molds with less injection pressure than is needed with other resins. This is a particularly important advantage with miniature parts.

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