IBS Filtran Selects DuPont™ Zytel® to Replace Metal with Plastic in the New Daimler NAG3 Automatic Transmission

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DuPont is Giving Shape to Smart Ideas as Evident in New Daimler NAG3 Production-Ready Oil Pan

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.

At K show 2016, DuPont Performance Materials (DPM) and IBS Filtran demonstrate a new production-ready oil pan made of a high grade glass-fiber-reinforced material which is being used in Daimler’s state of the art nine-speed automatic transmission.

DuPont 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 (1,3kg 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.” – Wolfgang Stausberg (CTO, 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” – 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. 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.

Besides, 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 could be avoided.

DuPont™ 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.

DuPont Performance Materials (DPM) DuPont Performance Materials (DPM) is a leading innovator of thermoplastics, elastomers, renewably-sourced polymers, high-performance parts and shapes, as well as resins that act as adhesives, sealants, and modifiers. DPM supports a globally linked network of regional application development experts who work with customers throughout the value chain to develop innovative solutions in automotive, packaging, construction, consumer goods, electrical/electronics and other industries. For additional information about DuPont Performance Materials, visit plastics.dupont.com.

DuPont (NYSE: DD) has been bringing world-class science and engineering to the global marketplace in the form of innovative products, materials, and services since 1802. The company believes that by collaborating with customers, governments, NGOs, and thought leaders we can help find solutions to such global challenges as providing enough healthy food for people everywhere, decreasing dependence on fossil fuels, and protecting life and the environment. For additional information about DuPont and its commitment to inclusive innovation, please visit http://www.dupont.com.

IBS FILTRAN GmbH part of FILTRATION Group. IBS FILTRAN is a world leader in the manufacturing of filter systems for automatic transmissions. With development and production sites in Germany, USA, China and Mexico, as well as partner companies in Korea and Japan, the company faces global customer requirements through specific, innovative system solutions.

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Sandrine Gessier
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