In a claimed breakthrough for structural automotive components, DuPont has announced that Zytel nylon resin has replaced steel in exhaust system parts on all Volkswagen vehicles built on the current Golf platform. The company says that the result is a 50% weight reduction on the component.
“This is significant because a key priority today for automotive original equipment manufacturers (OEMs) is weight reduction to improve fuel economy and reduce emissions,” said Keith J. Smith, vice president and general manager – DuPont Engineering Polymers.
The new Golf catalytic converter bracket, which experiences temperatures up to 175 degrees Celsius due to its proximity to the engine, was previously a complex metal/rubber part which required multiple assembly steps. The new component is a claimed global first, as a metal to plastics transition had not been attempted for parts such as these, which must withstand dynamic forces, chemical exposure and high temperatures.
In addition to the nearly 50% weight reduction, the new all-plastic design also makes possible more efficient, one-step assembly, DuPont says.
