Case Study: GM Gets Stiffness, Stability and More with Hytrel® for Airbag Doors
Hytrel® thermoplastic polyester elastomer ensures neat easy assembly and secure retention for passenger-side airbag doors.
Application Description
Several GM vans and trucks have passenger-side airbag deployment doors injection molded from Hytrel® DYM 500BK. This grade is tailor-made for relatively large, flat designs such as the airbag door installed on GM Astro/Safari minivans, C/K trucks and GMT 600 vehicles. These parts measure approximately 13 by 5 in. (33 by 13 cm).
Materials Selected and Why
Hytrel® DYM 500BK was developed to provide the stiffness and stability required for relatively large airbag doors. Its flex modulus is 500 MPa (72 kpsi) at 22°C (73°F). Like other members of the Hytrel® DYM family, DYM 500 also fulfills requirements for low-temperature ductility, impact resistance, low warp, excellent surface appearance and good paint adhesion without priming.
Benefits Gained
- Stability, fit and finish – The stiffness of Hytrel® DYM 500 ensures neat, easy assembly and secure retention of the door during normal service (i.e., when the airbag is not deployed).
- Easy to paint – Unlike some competitive materials, Hytrel® provides strong, reliable adhesion without costly priming or pretreatment steps.
- Low-cost assembly – The design permits assembly without fasteners. Molded-in windows in the door's integral flange allow it to mate with hooks in the metal airbag housing.
- Development support – DuPont engineers worked closely with GMC, Delphi Interior and Lighting Systems, TRW and Mayco Plastics in tailoring material performance and developing the design of the Astro/Safari door.
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