Case Study: Integration of rocker cover and air cleaner cuts costs, saves space
Zytel® nylon replaces multiple metal parts to create an integrated rocker cover and air cleaner.
Application Description
The 1998 Hyundai Atoz uses an integrated rocker cover/air cleaner made of 35% glass-reinforced Zytel® nylon 6,6 resin. The unit is used on Hyundai's Epsilon 0.8/1.0L engine.
Materials Selected and Why
DuPont™ Zytel® nylon 6,6 resin with 35% glass reinforcement met the needs for toughness, strength, high temperature resistance, chemical resistance and suitability for molding complex, multifunctional parts.
Benefits Gained
- Cost savings – In replacing metal parts, the integrated rocker cover/air cleaner cut system costs by 20%. Key savings factors included a reduction in part count from 51 to 34, the use of only two wire clamps instead of four, a cut in breather hose length and a 50% decrease in assembly hours.
- Space savings – The integrated design takes less space in the small car's engine compartment.
- Lighter weight – The new unit reduced weight by 20%.
- Crucial technical support – When warpage problems with the air cleaner housing arose during molding trials, DuPont engineers used sophisticated computer analysis techniques to recommend a change in the mold's gate location and runner design. The changes brought the part well within Hyundai's design specifications.
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