During an annual awards ceremony held by the Society of Plastics Engineers (SPE) Automotive Division on November 7 in Livonia, Mich., Cooper-Standard Automotive was honored with three finalist awards in the Most Innovative Use of Plastics category. These components, found in several new Nissan vehicles, use DuPont™ Zytel® HTN PPA which is designed to deliver significant cost, weight and performance improvements.
The three innovative assemblies – primarily in Heating, Ventilation and Air Conditioning (HVAC) and fluid transfer systems – were redesigned in plastic to integrate multiple functions, simplify attachments and final assembly, and take advantage of Cooper-Standard’s patented overmolding and joining processes to significantly reduce part count and improve performance. Cooper-Standard Automotive Inc., headquartered in Novi, Mich., is a leading global automotive supplier specializing in the manufacture and marketing of systems and components for the automotive industry.
The first assembly is an electric water valve assembly for the Nissan Titan, Armada and Quest that taps the strength, stiffness, chemical and moisture resistance of Zytel® HTN PPA to help enable a new, integrated design that reduces four component parts into one assembly for significant cost savings and a 40 percent weight savings. Cooper-Standard’s new design also delivers performance improvements, such as reducing pressure drop, current draw and internal/external leakage, which results in significant boost in air conditioning and heater performance.
“This is a first in terms of being able to singularly package a multi-functional water valve assembly,” said John Croft, director of Business Development, Cooper-Standard’s Fluid Systems Division. “After studying the initial design and previous components, we saw the opportunity to integrate a multitude of functions, relying on our patented overmolding hose connecting and integrated bracketing technologies, as well as the high performance/ease of processing characteristics of Zytel® HTN PPA.
Cooper-Standard’s electric water valve assembly was named finalist in the SPE Automotive Division’s Most Innovative Use of Plastics - Powertrain category.
The second assembly is an electric brushless pump for rear HVAC systems on the Nissan Quest. It is at the heart of an innovative design that incorporates 11 discrete components into one integrated assembly, cuts weight by one-third, streamlines packaging significantly, increases the motor’s life expectancy by 500 percent and greatly enhances vehicle cabin comfort.
“This application draws from our competency in motors and patented processes for overmolding,” said Tim Wade, product development engineer, Cooper-Standard’s Fluid Systems Division. “The patented motor is a three-phase, bi-polar inner rotor design that protects against reverse polarity and over-voltage and incorporates an integrated soft-start feature that reduces noise, vibration and harshness, or NVH.”
The electric brushless pump for rear HVAC systems was named a finalist in the SPE Automotive Division’s Most Innovative Use of Plastics - Chassis category.
The third assembly is a transmission thermal valve assembly for the Nissan Sentra that takes half the weight out of a heavy, multi-piece metal component, integrates multiple functions, eliminates multiple subassemblies and fasteners, streamlines processing, and eliminates cumbersome metal crimp and secondary welding processes. Costly fittings are eliminated. The use of over-molded brackets accomplish two functions - joint sealing and vehicle mounting interface - helping eliminate potential leak paths, for better performance and quality assurance.
“This assembly, critical in transferring fluid, really shows what can be achieved by using plastics instead of metal and designing to integrate functions,” said Richard Stonely, product development engineer, Cooper-Standard’s Fluid Systems Division. “The assembly is deceptively simple; it uses three unique and patented processes to join rubber and plastic to metal and showcases some of our innovative joining technologies.”
The transmission thermal valve assembly was named a finalist in the SPE Automotive Division’s Most Innovative Use of Plastics Division-Powertrain category.
“Zytel® HTN PPA was the perfect choice in these applications,” said Jay Patel, DuPont Automotive market development manager. “It offers the heat, chemical and moisture resistance to withstand the tougher under hood applications so that design engineers can move beyond metals and enjoy the design freedom inherent in thermoplastics. At the same time, Zytel® HTN PPA is among the easiest high-performance engineering polymers to process.”
DuPont Engineering Polymers manufactures and sells Zytel® nylon and Zytel® HTN PPA, Crastin® PBT, Rynite® PET, Delrin® acetal, Hytrel® TPC-ET, DuPont™ ETPV engineering thermoplastic vulcanizates, Minlon® mineral reinforced nylon, Thermx® PCT, Tynex® filaments, Vespel® parts and shapes, Zenite® LCP, to global aerospace, appliance, automotive, consumer, electrical, electronic, industrial, sporting goods and other diversified industries.
DuPont is a science-based products and services company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food; building and construction; communications; and transportation.
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Caption Photo 1:
Pictured is the Nissan Titan electric water valve assembly made of DuPont™ Zytel® HTN PPA and manufactured by Cooper-Standard.
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Caption Photo 2:
The electric brushless pump assembly for rear HVAC systems on the Nissan Quest reduces weight and streamlines packaging. It is manufactured of DuPont™ Zytel® HTN PPA by Cooper-Standard.
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Caption Photo 3:
The transmission thermal valve assembly of DuPont™ Zytel® HTN PPA for the Nissan Sentra is manufactured by Cooper-Standard.