The industry’s first injection-molded thermoplastic windshield wiper bracket (nosecone) system debuts on the 2003 Lincoln Town Car, delivering significant cost and weight benefits. The system, made of DuPont™ Rynite® post-consumer recycled PET polyester resin, eliminates a significant number of post-finishing operations and reduces weight approximately 10 percent to deliver significant production cost savings compared to a previous component of SMC (sheet molding compound).

The nosecone, located just below the lower edge of a windshield inside the engine compartment, supports and positions the windshield wiper module and provides a seal against the hood.

A team from Ford Motor Co., Carlisle Engineered Products, Valeo and DuPont Engineering Polymers collaborated on design and engineering for the nosecone, configuring the shape to accommodate under-hood engine packaging requirements. Replacing the previous SMC version also eliminated exposed glass fibers, improving part handling and assembly.

“This is the first step in a major shift for the industry related to wiper systems,” said Gary Skrypec, Carlisle senior product engineer. “Carlisle’s innovative design made the best use of post-consumer content material and DuPont technical support to reduce cost and weight. These capabilities also allow a manufacturing process that enables greater design flexibility to meet new under-the-hood packaging requirements.”

“The inherent design flexibility of thermoplastics often plays a critical role in delivering greater innovation and cost savings,” said Chris McBride of DuPont Engineering Polymers. “Thermoplastics open the opportunity to mold in added functionality and eliminate secondary operations. Rynite® PET provides the stiffness, flatness and structural capabilities needed for large, load-bearing parts, including forces from wiper motor torque. The fact that we were able to use post-consumer recycled content adds another level of environmental sustainability to Ford vehicle production.”

Headquartered in Chardon, Ohio, with engineering, sales and marketing operations in Livonia, Mich., Carlisle Engineered Products (CEP) is a technically diverse and innovative supplier of automotive heating and cooling, wiper and HVAC, and air induction solutions (www.cepcarlisle.com). CEP is a global, full-service automotive supplier with 14 facilities located strategically around the world. The firm delivers complete engineering and design support while providing small to large-size automotive components to OEMs and all three tiers of suppliers. CEP offers customers in-depth expertise working with high performance and reinforced resins along with demonstrated just-in-time delivery capabilities.

Valeo is an independent industrial group fully focused on the design, production and sale of components, integrated systems and modules for cars and trucks. Valeo ranks among the world's top automotive suppliers.

DuPont is a science company. Founded in 1802, DuPont puts science to work by solving problems and creating solutions that make people’s lives better, safer and easier. Operating in more than 70 countries, the company offers a wide range of products and services to markets including agriculture, nutrition, electronics, communications, safety and protection, home and construction, transportation and apparel.

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2/19/03

Editor’s note: DuPont™ and Rynite® are a trademark and a registered trademark of E.I. du Pont de Nemours and Company.

Photo Caption: Pat Granowicz of DuPont Engineering Polymers, who completed much of the extensive FEA mold analysis of this component, is pictured left of Gary Skrypec, Carlisle senior product engineer.
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