Polyamide replaces metal in production-ready oil pan

DuPont has collaborated with IBS Filtran, a leading supplier of oil filter systems for transmission in the automotive industry, to optimize 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 Zytel　nylon resin portfolio (Zytel 70G35 HSLRA4) for the multifunctional lower shell. Replacing metal with Zytel reduces cost by saving on weight (1.3 kg 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,” commented Wolfgang Stausberg, CTO at IBS Filtran.

Drawing on the significant 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 Zytel for this project and produce this unique highly integrated oil pan,” said Franz Spitznagel, Senior Development Programs Manager at DuPont Performance Materials.

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 Zytel combines low warpage, easy processing and laser weldability. It 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. Further, transmission oil resistance and creep resistance at 150 degrees, this grade of Zytel is the perfect fit for this kind of application. DuPont Zytel 70G35 is said to offer the right blend of strength, stiffness and fatigue resistance to stand up to the load and stress such a demanding use calls for.