Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:


A European debut in polymer: Bracket made of DuPont™ Zytel® used for ‘hot-end’ of exhaust systems

anvisgroup of Bad Soden-Salmünster, Germany, working in cooperation with Volkswagen, has developed the first catalytic converter bracket for cars to be made from an engineering thermoplastic.

Due to its position – in close proximity to the engine where temperatures of up to 175 °C, high static and dynamic forces, moisture and chemicals combine – steel plates had previously been considered irreplaceable for such applications.

Photo: DuPont
For the first time in Europe, a polymer bracket (moulded in Zytel®) is used to secure the ‘hot-ends’ of exhaust systems to the underside of a car. The two-component part, which uses the rubbers EPDM (black) and VMQ (red) as well as the nylon, was developed by anvisgroup in cooperation with Volkswagen. The part’s first serial application is on all vehicles built on the current Golf platform.

Yet anvisgroup has proven the opposite by developing an innovative, two-component bracket based on glass-fibre reinforced DuPont™ Zytel® nylon and rubber. Since mid-2006, the design has proven itself at the ‘hot end’ of exhaust systems on all new vehicles belonging to Volkswagen’s so-called Golf platform (PQ35).

Manufacture of the newly-designed bracket starts with the injection-moulding of the cross-bar in Zytel®. During a second production phase, the rubber bearings, either made from EPDM (for diesel and smaller petrol engines) or the more heat-resistant silicon rubber VMQ (high-performance petrol engines) are moulded on. Finally the aluminium bushings, required to secure the bracket, are assembled by force fitting.

Mounted between the exhaust manifold and the catalytic converter, the two-component part provides flexible and attenuating support for the exhaust system in the x-direction, while absorbing static and dynamic loads in the y- and z-directions. Thus it prevents, for example, the exhaust system from jolting forward in the event of a sudden deceleration, which could otherwise damage the sensitive, flexible metal bellows that decouples load change movements and vibrations between the engine and the exhaust system.

Comprehensive testing, carried out by anvisgroup, showed that Zytel® 70G35HSL, a hydrolysis-stabilised PA66 with 35 wt. % glass fibres, can meet OEM requirements for dependability for the entire lifecycle of the vehicle. “The component was subjected to the kind of extreme conditions that you would only experience in real life if you were to drive a car and heavy trailer uphill on a potholed road for hundreds of kilometres,” comments Gerhard Heckmann, product group manager for exhaust system mountings and decouplings at anvisgroup. “Our test results confirmed that, even then, the cross-bar made of glass-fibre reinforced Zytel® continues to perform faultlessly. Indeed the new catalytic converter bracket offers high levels of safety over its entire lifetime.”

In addition, the new design offers further decisive benefits: Firstly, the polymer component weighs only 165g and is therefore considerably lighter than its metal counterpart, which comes in at 300g. Secondly, it provides the opportunity for cost-efficiencies during manufacture because, for example, surface protection is no longer required to prevent corrosion. “With the completion of this project we have been able to implement the first polymer mounting for the ‘hot end’ of the exhaust module. Hence there is nothing to prevent the development of a polymer alternative for the ‘cold end’ as well,” concludes Heckmann.

anvisgroup develops innovative functional solutions for vehicle dynamics, comfort and safety. Its product portfolio includes chassis components, power-plant suspension systems, exhaust system mountings and decoupling elements/TMD. As a global innovator of acoustic- and vibration-control solutions for the entire vehicle, anvisgroup and its 2200 employees achieved a global turnover of 260 million Euros in 2006.

The DuPont Engineering Polymers business manufactures and sells Crastin® PBT and Rynite® PET thermoplastic polyester resins, Delrin® acetal resins, Hytrel® thermoplastic polyester elastomers, DuPont™ ETPV engineering thermoplastic vulcanizates, Minlon® mineral reinforced nylon resins, Thermx® PCT polycyclohexylene dimethyl terephthalate, Tynex® filaments, Vespel® parts and shapes, Zenite® LCP liquid crystal polymers, Zytel® nylon resins and Zytel® HTN high-performance polyamides. These products serve global markets in the aerospace, appliance, automotive, consumer, electrical, electronic, industrial, sporting goods and many other diversified industries.

DuPont is a science-based products and services company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food; building and construction; communications; and transportation.

The DuPont Oval Logo, DuPont™, The miracles of science™ and all product names denoted with ® are registered trademarks or trademarks of DuPont or its affiliates.


Note to the editor:
This press release is based on information provided by:
anvis Deutschland GmbH
Hanauer Landstrasse 16, 63628 Bad Soden-Salmünster, Germany
Contact: Gerhard Heckmann
Phone: ++49 (0) 60 56 78 - 73 19
Fax: ++49 (0) 60 56 78 - 5 73 19

Horst Ulrich Reimer | Du Pont
Further information:

More articles from Materials Sciences:

nachricht The search for dark matter widens
21.03.2018 | American Institute of Physics

nachricht Scientists have a new way to gauge the growth of nanowires
19.03.2018 | DOE/Argonne National Laboratory

All articles from Materials Sciences >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Researchers at Fraunhofer monitor re-entry of Chinese space station Tiangong-1

In just a few weeks from now, the Chinese space station Tiangong-1 will re-enter the Earth's atmosphere where it will to a large extent burn up. It is possible that some debris will reach the Earth's surface. Tiangong-1 is orbiting the Earth uncontrolled at a speed of approx. 29,000 km/h.Currently the prognosis relating to the time of impact currently lies within a window of several days. The scientists at Fraunhofer FHR have already been monitoring Tiangong-1 for a number of weeks with their TIRA system, one of the most powerful space observation radars in the world, with a view to supporting the German Space Situational Awareness Center and the ESA with their re-entry forecasts.

Following the loss of radio contact with Tiangong-1 in 2016 and due to the low orbital height, it is now inevitable that the Chinese space station will...

Im Focus: Alliance „OLED Licht Forum“ – Key partner for OLED lighting solutions

Fraunhofer Institute for Organic Electronics, Electron Beam and Plasma Technology FEP, provider of research and development services for OLED lighting solutions, announces the founding of the “OLED Licht Forum” and presents latest OLED design and lighting solutions during light+building, from March 18th – 23rd, 2018 in Frankfurt a.M./Germany, at booth no. F91 in Hall 4.0.

They are united in their passion for OLED (organic light emitting diodes) lighting with all of its unique facets and application possibilities. Thus experts in...

Im Focus: Mars' oceans formed early, possibly aided by massive volcanic eruptions

Oceans formed before Tharsis and evolved together, shaping climate history of Mars

A new scenario seeking to explain how Mars' putative oceans came and went over the last 4 billion years implies that the oceans formed several hundred million...

Im Focus: Tiny implants for cells are functional in vivo

For the first time, an interdisciplinary team from the University of Basel has succeeded in integrating artificial organelles into the cells of live zebrafish embryos. This innovative approach using artificial organelles as cellular implants offers new potential in treating a range of diseases, as the authors report in an article published in Nature Communications.

In the cells of higher organisms, organelles such as the nucleus or mitochondria perform a range of complex functions necessary for life. In the networks of...

Im Focus: Locomotion control with photopigments

Researchers from Göttingen University discover additional function of opsins

Animal photoreceptors capture light with photopigments. Researchers from the University of Göttingen have now discovered that these photopigments fulfill an...

All Focus news of the innovation-report >>>



Industry & Economy
Event News

Virtual reality conference comes to Reutlingen

19.03.2018 | Event News

Ultrafast Wireless and Chip Design at the DATE Conference in Dresden

16.03.2018 | Event News

International Tinnitus Conference of the Tinnitus Research Initiative in Regensburg

13.03.2018 | Event News

Latest News

TRAPPIST-1 planets provide clues to the nature of habitable worlds

21.03.2018 | Physics and Astronomy

The search for dark matter widens

21.03.2018 | Materials Sciences

Natural enemies reduce pesticide use

21.03.2018 | Life Sciences

Science & Research
Overview of more VideoLinks >>>