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Table of Contents
Page
Why Blow Moulding ...............
2
DuPonts offering ....................
2
Polyester resins ........................
2
Nylon resins .............................
2
Under-bonnet components .......
2
Start
with
DuPont
Page
3
3
3
4
4
8 to 15
3
3
B
A
C
3
4
1
4
B
A1
2
4
1
A1
1)
2)
3)
4)
A)
B)
C)
Clean air
Crankcase housing venting hose
Recycled air
Recycled charged air
Air filter
Charger
Heat exchanger for charged air
A)
A1)
B)
C)
D)
E)
Coolant radiator
1)
Header tanks in ZYTEL
2)
Oil cooler
3)
Air duct
4)
Heat exchanger for car interior
Air conditioner
Requirements
Temperature
Pressure
Chemical resistance
Suitable polymers
Pressure range
1,2 2 bar charge pressure
Chemical resistance
Oil, blow-by gas and petrol
Typical fatigue test
Stress cycles
Pulsating pressure range
Test medium
Temperature
Ambient air temperature
Test frequency
1000 000
1,2 2 bar
air
132 2 C
85 5 C
0,5 1 Hz
Suitable polymers
Benefits of HYTREL :
Greater toughness (5 10 times vs. rubber)
Longer life cycle
Better dimensional stability
No ballooning at high speed
Superior low temperature flexibility
Higher wear resistance
Lower permeation of oil and grease
Weight reduction against rubber
3
Continuous extrusion
The parison is extruded continuously by constantly
rotating the screw of the plasticising unit.
The process is very simple but requires the use of
high melt strength polymers to be able to make
long parts. A limitation is often the weight of the
parison, as it has a tendency to elongate or collapse
under its own weight while being extruded relatively slowly out of the die. Continuous extrusion
machines are generally lower cost vs. other types.
Europe :
**
Accumulator head
In this process, the screw of the plasticising unit is
rotating continuously and accumulates the molten
polymer into a cylinder. The melt is then pushed
out through the die by a piston in a very short time.
This system has one advantage: it allows the use of
lower melt strength resins as the parison does not
have to hang so long (typically one fifth of the time
compared to the continuous process) before being
moulded. The machines are however more expensive but it is normally offset by more flexibility.
Multi-layer extrusion
Equipment is available for continuous extrusion or
with accumulator head. Of importance is that several polymers can be extruded into a multi-layer
parison. The thicknesses of the individual layers
and the combination of polymers can be varied.
The benefit is a structure which only uses the minimum amount of each individual polymer to
achieve the required properties at the minimum
cost.
3-layer coextrusion
1) Main extruder :
Inner layer
2) Satellite extrude r 1 : Middle layer (e.g. recycled material)
3) Sattelite extruder 2 : Outer layer (e.g. high heat, abrasion
resistant, styling or barrier)
Hard
Soft
Polyesters
CRASTIN*
HYTREL/ETP
Nylons
ZYTEL BM
ZYTEL BM 7300 FN
Sequential
1)
2)
3)
4)
1) Injection mould
2) Blow mould
3) Stripping
Injection mould
Blow mould
Stripping
Core pin temperature
conditioning
Hard
Soft
Hard
Two layer trial inner HYTREL 5612
for good flex performance outer
layer is HYTRTEL ETP 1383 for
high heat resistance
Left
end
HARD
Centre
bellow
SOFT
Right
end
HARD
CRASTIN
HYTREL
CRASTIN
XMB6400 ETP1383 XMB6400
Y
X
Z
The mould
starts moving
The mould finishes moving
Y
X
Starting
point
4) Comparison
Traditional air flow pipe
Parts
Assembly
operations
Pipe
Rubber hose
Hose band
Washer
Bolt
Total
23 pieces
24 operations
1) Flexibility of design
2) Variety of resins
Polyesters
Nylons
Hard
Soft
CRASTIN
XMB6400
HYTREL/ETP
ZYTEL BM
7300T HSL
ZYTEL BM
73G25T HSL
ZYTEL BM
7300 FN
Parts
Assembly
operations
Pipe
Rubber hose
Hose band
Washer
Bolt
Total
7 pieces
8 operations
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Helphos
VW - Corrado
HYTREL HTR 4275 BK
Commercial
Air duct with welded-on attachment and
metal inserts
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Kaiser
Audi
HYTREL HTR 4275 BK
Commercial
Achieved noise reduction
With integrated seal
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Bellow La Bonette
Vhicules Industriels
Renault
ALCRYN 2070 BK
Commercial
ALCRYN 2070 BK was chosen because of its
good processing and weathering characteristics
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Kaiser
Audi
HYTREL HTR 4275 BK
Commercial
Air duct with integrated moulded-in seals
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Helphos
VW
HYTREL HTR 4275 BK
Commercial
Attachment integrated
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
10
Air duct
Helphos
VW - Golf A3
HYTREL HTR 4275 BK
Commercial
Metal inserts
moulded on attachment
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Helphos
VW
HYTREL HTR 4275 BK
Commercial
Moulded on attachment
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Kaiser
Audi
HYTREL HTR 4275 BK
Commercial
Replaced ECO and saved about 40% of the
component cost due to integrated seals and
easier assembly
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Helphos
VW
HYTREL HTR 4275 BK
Commercial
Integrated attachment and welded on
attachment
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Helphos
VW
HYTREL HTR 4275 BK
Commercial
Metal inserts
Moulded on attachment
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Kayser
Audi
HYTREL HTR 4275 BK
Commercial
This duct replaced ECO and saved about
40% of the component cost due to easier
assembly and integrated seals
Test Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
VW Air ducts
Helphos
VW
HYTREL HTR 4275 BK
Commercial
Several different air ducts
Commercial Application
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Helphos
VW
HYTREL HTR 4275 BK
Commercial
Integrated attachment
Test Application
12
Air duct
Kaiser
Audi
HYTREL HTR 4275 BK
Commercial
Replaced ECO
Application :
Moulder :
Test mould
Krupp Kautex Machine Manufacturer
OEM :
Grade :
Status :
Comment :
ZYTEL BM
Test
Sequential Co-extrusion
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Kautex UK
Ford - Zeta engine
ZYTEL BM
Commercial
Ford prefers ZYTEL for higher temperature
requirement
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Resonator
Kautex UK
Ford - Mondeo
ZYTEL BM
Commercial
Ford prefers ZYTEL for high temperature
requirements
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Phoenix
VW
HYTREL HTR 4275 BK
Commercial
The crank case vent goes in the studs integrated in the part that is why oil resistance
at elevated temperature
(150 C) is required
Test Application
Application :
Moulder :
Test mould
Krupp Kautex Machine Manufacturer
OEM :
Grade :
Status :
Comment :
13
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Air duct
Kayser
Audi
HYTREL HTR 4275 BK
Commercial
With integrated moulded-in seals
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
14
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
CVJ Boot
Contitech
PSA
HYTREL HTR 4275 BK
Commercial
In use on the wheel sides. HYTREL was chosen because of its excellent low temperature
flexibility.
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
CVJ Boot
Contitech
Ford - Mondeo
HYTREL HTR 8105 BK
Commercial
Bellows made from HYTREL are used on
wheel and engine side, 4 bellows are used
on each vehicle
Development Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
Commercial Application
Application :
Moulder :
OEM :
Grade :
Status :
Comment :
CVJ Boot
Contitech/Mller Werke/Paguag
VW (Golf)
HYTREL HTR 8105 BK
Commercial
VW choose HYTREL because of excellent
low temperature flexibility (no service failure at 50 C).
Commercial Application
Application :
Cooling pipe
Moulder :
DAF
HYTREL HTR 4275 BK
Development was not commercialised
OEM :
Grade :
Status :
BMW
PA 66, 30% glass reinforced
Commercial
Comment :
15
Benelux
Du Pont de Nemours (Belgium)
Antoon Spinoystraat 6
B-2800 Mechelen
Tel. (15) 44 14 11
Telex 22 554
Telefax (15) 44 14 09
Hellas
C. G. Lazarakis Ltd
Valaoritou Street 17
GR-10671 Athina
Tel. (01) 361 84 11
Telex 219 037 LACO GR
Telefax (01) 362 09 30
Portugal
Mario Coelho
Rua do Campo Alegre, 672 - 1
P-4100 Porto
Tel. (2) 69 24 25/69 26 64
Telex 23 136 MACOL
Telefax (2) 600 02 07
Trkiye
Grillo Maden Ltd.
Inonu Caddesi 96/6
TR-80090 Taksim-Istanbul
Tel. (1) 149 83 10
Telex 24 271 GILO TR
Telefax (1) 144 51 13
Bulgaria
Du Pont Bulgaria
18, Tcherni Vrah Blvd.
Bldg. 2, Floor 5
BG-1407 Sofia
Tel. (2) 66 59 13/66 57 36
Telex 24 261 DUPONT BG
Telefax (2) 65 63 29/66 56 11
Isral
Gadot Chemical Terminals (1985) Ltd.
22, Shalom Aleichem Street
IL-633 43 Tel Aviv
Tel. (3) 528 62 62
Telex 33 744 GADOT IL
Telefax (3) 282 717
Romania
Aectra International Ltd
Distributor for DuPont
Strada Luterana 2 - 4
Hotel Bucuresti Corp. D2,
Etay 2, Ap. 6
Of. Postal 45-13
R-70741 Bucuresti
Tel. 14 34 14
Telex 92 512 DPX R
Telefax 13 50 75
United Kingdom
Du Pont (U.K.) Limited
Maylands Avenue
GB-Hemel Hempstead
Herts. HP2 7DP
Tel. (0442) 21 85 00
Telex 825 713 DUPONT G
Telefax (0442) 24 94 63
Ceskoslovensko
Du Pont - Conoco CS Spol. S.R.O.
Palc Kultury
5, Kvetna 65
CS-14009 Praha 4
Tel. (02) 422 641 to 422 646
Telex 121 834 DUPO C
Telefax (02) 499 209
Danmark
Du Pont Danmark
Branch of Du Pont Scandinavia AB
Parkall 292
DK-2605 Brndby
Tel. (43) 63 32 66
Telex 33 263 DUPONT DK
Telefax (43) 63 38 33
Deutschland
Du Pont de Nemours
(Deutschland) GmbH
DuPont Strae 1
D-61343 Bad Homburg
Tel. (06172) 87 0
Telex 410 676 DPD D
Telefax (06172) 87 15 00
Egypt
Medgenco International Trade Co.
13, El Bostan Street
ET-Cairo
Tel. (02) 392 78 66
Telex 93 742 MK UN
Telefax (02) 392 84 87
Espaa
Du Pont Ibrica S. A.
Tuset, 23, 1
E-08006 Barcelona
Tel. (3) 200 73 11
Telex 50 887 DUPO E
Telefax (3) 414 28 75
France
Du Pont de Nemours (France) S.A.
137, rue de lUniversit
F-75334 Paris Cedex 07
Tel. (1) 45 50 65 50
Telex 206 772 dupon
Telefax (1) 47 53 09 67
Start
with
DuPont
01.94
H-53702
Printed in Switzerland
Italia
Du Pont de Nemours Italiana S. p. A.
Via A. Volta, 16
I-20093 Cologno Monzese Mi
Tel. (02) 25 302 1
Telex 314 671 DUPIT I
Telefax (02) 27 300 969
Magyaroszg
Du Pont - Conoco Hungary KFT
Theokoely Ut. 137
H-1145 Budapest
Tel. (1) 183 51 40
Telex 202 805 DUPON H
Telefax (1) 251 43 45
Maroc
Deborel Maroc S. A.
Rsidence Firdaous
40, boulevard dAnfa - 10
MA-Casablanca
Tel. (2) 27 48 75
Telex 23 719 BOUKBEN
Telefax (2) 26 54 34
Norge
Nordic Polymers A/S
Niels Leuchsvei 99
N-1343 Eiksmarka
Tel. 67 14 28 70
Telefax 67 14 30 44
sterreich
Interowa
Frer-Haimendorf KG
Bruhausgasse 3-5
A-1050 Wien
Tel. (01) 512 35 71
Telex 112 993 IROWA A
Telefax (01) 512 35 71 12/
512 35 71 31
Polska
E. I. du Pont de Nemours & Co.
Warsaw Branch Office
Intraco Bldg - Floor 13
ul. Stawki 2
PL-00193 Warszawa
Tel. (2) 635 04 01
Telex 812 376 DUP PL
Telefax (2) 635 07 61
Asia Pacific
Du Pont Asia Pacific Ltd
Polymer Products
P.O. Box TST 98851
1122 New World Office Bldg East Wing
Salisbury Road
Kowloon, Hong Kong
Tel. (852) 734 53 45
Telex 46 296 DPTHK HX
Telefax (852) 724 44 58
Russia
Du Pont Russia
Yuzhinsky Pereulok 13/2
SU-103 104 Moskva
Tel. (095) 973 10 01
Telex 413 778 DUMOS SU
Telefax (095) 973 24 40
Schweiz/Suisse/Svizzera
Dolder AG
Immengasse 9
Postfach 14695
CH-4004 Basel
Tel. (061) 326 66 00
Telex 962 306 DOL CH
Telefax (061) 326 62 04
Slovenija
Du Pont de Nemours
International S.A.
Representative Office
16, Tolstojeva Ulica
61000 Ljubljana, Slovenija
Tel. (061) 34 43 93
Telex 31 108 BETI YU
Telefax (061) 34 43 93
USA
E. I. du Pont de Nemours & Co.
Wilmington, Delaware 19898
Tel. (302) 774 1000.
Telex 67 17 325 DUPONT
Suomi/Finland
Suomen Du Pont Oy
Lapinlahdenkatu 3A 20 (Lappviksgat)
PL 237
SF-00181 Helsinki
Tel. (90) 694 55 22
Telefax (90) 694 53 11
Sverige
Du Pont Scandinavia AB
Torshamnsgatan 35
S-164 86 Kista (Stockholm)
Tel. (08) 750 37 00
Telex 12 410 DUPONO S
Telefax (08) 750 90 41
South Africa
Du Pont de Nemours
International S.A.
South African Branch Office
1st Floor Howick Gardens
Howick Close, Waterfall Park
Vorna Valley Ext. 21, Midrand
Box 3332, Halfway House
Tel. (11) 315 38 80
Telex 426 513 DUPNT
Telefax (11) 315 42 57
This information corresponds to our current knowledge on the subject. It is offered solely to provide possible suggestions for your own experimentations. It is not intended, however, to substitute for any testing you may need to conduct to determine for yourself the suitability of our products for your particular purposes. This information may be subject to revision as new knowledge
and experience becomes available. Since we cannot anticipate all variations in actual end-use
conditions, DuPont makes no warranties and assumes no liability in connection with any use of
this information. Nothing in this publication is to be considered as a license to operate under or a
recommendation to infringe any patent right.
Engineering Polymers