DuPont has collaborated with IBS Filtran to optimise production and processing of Daimler car oil pans in nine speed automatic transmission.
The NAG3 (new automatic transmission) uses a thermoplastic polymer from DuPont’s Zytelnylon resin portfolio (Zytel 70G35 HSLRA4) for the multifunctional lower shell. According to DuPont, replacing metal with Zytelreduces cost by saving on weight (1,3kg versus a metal oil pan), providing design freedom without compromising on performance.
“We have had a strong relationship with DuPont for many years which invites the type of collaboration necessary to create revolutionary transmission systems addressing regulatory and consumer trends. This oil pan is an example of how working with the supply chain can produce cost-effective solutions that our consumers desire. With DuPont’s help, we developed an oil pan which links the need for core design and reduced manufacturing and assembly costs with energy efficiency,” said Wolfgang Stausberg, CTO, IBS Filtran.
Drawing on the expertise of IBS Filtran in filtration and plastic module design, the two plastic oil filters are fully integrated into the oil pan housing to meet the highly demanding specifications given the restricted installation space. “Replacing sheet metal is only possible via a full integration of anything which can be integrated. Working closely with IBS Filtran enabled us to use Zytelfor this project and produce this unique highly integrated oil pan,” explains Franz Spitznagel, Senior Development Programs Manager at DuPont Performance Materials.
DuPont states that the use of these types of thermoplastic polymers creates a significant opportunity for further functional integration of the oil pan with the rest of the transmission. This grade of Zytelcombines low warpage, easy processing and laser weldability. DuPonts continues, Zytel has an excellent balance of stiffness and toughness over a wide range of temperature, and in combination with a special rib design it withstands stone impacts of up to 200 km/h. For all this, its transmission oil resistance and creep resistance at 150 degrees, this grade of Zytel is the perfect fit for this kind of application.
According to DuPont, the integrated filter system uses the SmartMedia technology from IBS Filtran, where different filter media types are combined to significantly improve the filter performance on the suction side of the pump. Whereby an additional pressure filter can be avoided.
DuPont says its Zytel 70G35 offers the right blend of strength, stiffness and fatigue resistance to stand up to the load and stress such a demanding use calls for. It is the ideal material to use in this new transmission, which sets the trend for the future.
Image provided by DuPont
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