Case Study: Multi-functional bracket plate cuts cost of pedal module assembly
Molding large, complex part from Zytel® nylon resin reduces weight and saves assembly and installation costs.
Application Description
Mercedes-Benz A-Class compact cars have a pedal bracket plate injection molded from glass-reinforced DuPont™ Zytel® nylon. They are believed to be the first production cars to use molded plastic instead of die-cast aluminum for such a part. The plate is a large, complex part measuring 30 cm by 30 cm with integrally molded provisions for assembly with various other components of the pedal module and mounting on the bulkhead of the engine compartment. The design, developed with computer-aided finite-element methods, also incorporates structural ribbing.
Materials Selected and Why
Zytel®, containing nylon 6,6 with 35% glass fiber reinforcement, fulfills the bracket plate's requirements for strength, toughness, dimensional stability, low warp and thermal and chemical resistance.
Benefits Gained
- Low assembly, installation costs – The design incorporates a number of features and functions that facilitate assembly and installation of the car's pedal module with clips, bolts and plastic fasteners.
- Economical molding – Despite the part's relatively large size, molding cycles are short. The part requires no post-molding finishing or surface coating.
- Lighter weight – The plate weighs just 1.2 kg, about one-third less than a comparable aluminum part.
- Improved NVH performance – The vibration-absorbing characteristics of Zytel® nylon help isolate passengers from noise and vibrations generated in the engine compartment.
Please click here if you would like more information regarding this case study.
