VESPEL AUTOMOTI E - DuPont ® parts and shapes 5 ... become the driving force in the auto-motive...
Transcript of VESPEL AUTOMOTI E - DuPont ® parts and shapes 5 ... become the driving force in the auto-motive...
VespelOnly by DuPont
®
®
® DuPont registered trademarkAU
TO
MO
TI
E
VESPEL®
2
ContentsVespel® parts and shapes 5
Properties 6-7
Properties into benefits 8-9
Transmissions 10 -11
Electrical motors 12 -13
Brakes 14
Fuel systems 15
Turbo chargers and exhaust gas return systems 15
Other equipment 16
Opportunities 17
Summary of typical properties of Vespel® SPPolymide Resins 18
The Vespel® offering 19
VESPEL®
Under bonnet
• Fuel systems•Turbocharger• EGR• Vacuum pumps• Ignition• Starter• Belt tensioner
Transmissions
• Automatic gear boxes• Clutches
3
Electrical motors
• Window lift• Windscreen wiper• Sunroof• Wing mirror adjuster• Seat adjuster• Steering wheel height
adjuster
Brake systems
• ABS• Wear pad sensors
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Global company
Finished-parts supplier
Proven applications intransmissions andelectrical motors
ISO 9001 certified and several customer
certifications
Cost effective andinnovative design
Continuous R&Dinvestment
More than 15 years in the automotive
industry
Understanding of technical, quality andsupply requirements
Testing facility for seal rings, bushings
and washers
Partnership with car manufacturer
suppliers
Specialists in wear and friction
components
VESPEL® PARTS ANDSHAPES
VESPEL®
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PROPERTIES...
Excellent compressive properties
- High elastic limit- Non brittle- High deformation capability
Insulation
- Thermal- Electric
Wear and friction problemsolver
- Low CF- Low wear rate- Constant CF
Machinability
- Similar to brass- Quality 7 tolerances achievable
Chemical compatibility
- With oil- With solvents- With fuels (diesel/gasoline)
Temperature resistance
- No melting point- No Tg- Continuous use 290°C, excursions to 480°C
Polymer
- Light weight- Dampens vibration
Impact resistance
High PV capability with orwithout lubrication
- PVvalue (dry) = 12 MPa m/s- PVvalue (lubricated) = 40 MPa m/s- Instantaneous PVlimit (lubricated) = 140 MPa m/s
Electrical insulation
- Parts retain their good electricalproperties at high temperatures
...I
NT
O B
EN
EF
ITS
Tem
pera
ture
resi
stan
ce
- No
mel
ting
poin
t- N
o Tg
- Con
tinuo
us u
se 2
90°C
, ex
curs
ions
to 4
80°C
Po
lym
er
- Lig
ht w
eigh
t- D
ampe
ns v
ibra
tion
Imp
act
resi
stan
ce
Hig
h P
V c
ap
ab
ility
wit
h o
rw
ith
ou
t lu
bri
cati
on
- PV
valu
e (d
ry) =
12
MP
a m
/s- P
Vva
lue
(lubr
icat
ed) =
40
MP
a m
/s- I
nsta
ntan
eous
PV
limit
(lubr
icat
ed) =
14
0 M
Pa
m/s
- W
ork
s su
ccess
fully
in
th
eh
ott
est
are
as
of
the e
ng
ine
- W
ith
stan
ds
all
car
ass
em
bly
pro
cess
es
- C
an
be o
verm
ou
lded
- S
afe
ty
- W
eig
ht
red
uct
ion
- Lo
w in
ert
ia f
or
mo
vab
le
com
po
nen
ts
- N
ois
e r
ed
uct
ion
- S
uit
ab
le f
or
hig
h f
req
uen
cyvib
rati
on
- R
esi
sts
imp
act
- C
an
ru
n w
ith
ou
t lu
bri
cati
on
- R
ed
uct
ion
of
con
tact
are
a,
i.e. p
art
siz
e
- In
crease
d s
afe
ty m
arg
in in
case
of
mis
use
- P
art
s w
ill r
un
dry
sh
ou
ld
lub
rica
tio
n f
ail
- Lo
wer
warr
an
ty c
ost
s
Ele
ctri
cal in
sula
tio
n
- Par
ts re
tain
thei
r goo
d el
ectri
cal
prop
ertie
s at
hig
h te
mpe
ratu
res
6
PR
OP
ER
TIE
S..
.
- E
asy
ass
em
bly
- N
o b
reakag
e
- S
ealin
g c
om
plia
nce
- C
an
pro
tect
oth
er
com
po
nen
ts
- Lo
ng
er
life
- R
elia
bili
ty
- R
ed
uce
d p
ow
er
con
sum
pti
on
- R
ed
uce
d w
arr
an
ty c
ost
s
- Fast
pro
toty
pin
g
- C
om
ple
x g
eo
metr
ies
an
d t
igh
tto
lera
nce
s ach
ievab
le w
ith
seco
nd
ary
mach
inin
g
- N
o c
orr
osi
on
- W
ork
s su
ccess
sfu
lly in
co
nta
ctw
ith
all
au
tom
oti
ve c
hem
icals
Exce
llen
t co
mp
ress
ive
pro
pert
ies
- Hig
h el
astic
lim
it- N
on b
rittle
- Hig
h de
form
atio
n ca
pabi
lity
Th
erm
al in
sula
tio
n
- Can
pro
tect
oth
er c
ompo
nent
s
Wear
an
d f
rict
ion
pro
ble
mso
lver
- Low
CF
- Low
wea
r rat
e- C
onst
ant C
F
Mach
inab
ility
- Sim
ilar t
o br
ass
- Qua
lity
7 to
lera
nces
ach
ieva
ble
Ch
em
ical co
mp
ati
bili
ty
- With
oil
- With
sol
vent
s- W
ith fu
els
(die
sel/g
asol
ine)
In the last few decades, automaticgearboxes and transmissions haveincreasingly replaced manual devicesin cars, trucks, tractors and off-roadvehicles.
Driving comfort, optimization ofengine torque output, fuel saving andnew pollution regulations have nowbecome the driving force in the auto-motive industry.
Thrust washersWith its very high PVlimit of 12MPa.m/s in dry conditions coupledwith good compressive properties,Vespel® has been successful in appli-cations such as thrust washers inhydraulic transmissions and also insplit flywheels (clutches) coupledwith manual gearboxes. Vespel®
washers (with outside diameters ofup to 90 mm) have proved theirsuperior performance in tractor, truckand car transmissions by working in anormal oil mist environment andreaching PVs of up to 40 MPa.m/sand speeds of 7000 rpm. They caneven accept instantaneous PVs of 140MPa.m/s during gear changes in aforced lubrication environment.
The flexibility of Vespel® means thatwhen the loading and speed condi-tions are known the design can opti-mize contact area (outside and insidediameters). Features can also beadded to centre the part or to preventrotation in order to select the slidingsurface.
The design of hydraulic units is com-plex as it has to take into considera-tion such aspects as: leakage control,sealing, vibrations, high loads &speeds, high temperatures generatedby friction, durability and reliability.In certain extreme conditionsmechanical components, normallylubricated by the surrounding oil,may have to run dry, generatingexcess heat and leading to failure.
The introduction of Vespel® as wearand friction components such asThrust Washers, Seal Rings andValve Seats, has increased both per-formance and lifetime. At the sametime overall costs can be reduced by:
• easier assembly of seal rings
• elimination of forced lubrication
• elimination of heat treatment onmating material
• wider tolerances on machined mating surfaces
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VESPEL®
TR
AN
SM
ISS
ION
S
Radial grooves, which can be manu-factured without additional machining,facilitate lubrication and thereforeincrease PVlimit. Vespel® thrustwashers resist static load without creepand impacts, and avoid the seizingoften seen with metal/metal solutions.
Seal ringsVespel® seal rings operating inside thetransmission work dynamically,mainly in the radial direction but alsosometimes in an axial linear direction.Their function is to provide a sealbetween the shaft and the housing atgiven pressures and speeds so thatclutches, i.e. gears, can be actuated.
A small leakage is neverthelessrequired here in order to lubricateother components such as needlebearings and gears, and also to avoidhigh surface temperatures. Lifetimeand reliability are very important as they both influence the shifting operations.
Vespel® seal rings are designedaccording to customers requirementsof speed, pressure, temperature,desired leakage rate, mating materialand allowable wear.
Some of today's existing and provenVespel® applications are:
• Tractor transmissions at speeds ofabout 2,500/3,000 rpm diameters upto 80 mm and pressures of 12 bars.
• Passenger car automatic gearboxesat speeds of 7,000 rpm for diametersup to 52mm and pressures of 12 bars.
• Automotive continuous velocitytransmissions (CVT) at speeds up to10,000 rpm for diameters about20mm and pressure of 20 bars.
Valve seatsThe reduction and control of oil leak-age within the transmission is animportant issue. The sealing compli-ance and resilience properties of
Vespel® make it the ideal material forvalve seats. They can be easily press-fitted into the housing and can elimi-nate the need for an "O" ring.Operating successfully in pressures of20 MPa, Vespel® valve seats havedemonstrated a high level of resis-tance to the abrasive action of metalparticles in dirty hydraulic oil whileproviding a reliable sealing perfor-mance over time while resistingimpact.
Seal ring gap type and dimensionsare calculated to provide appropriateleakage at the given temperatures andpressures. Wear can be minimized byoptimizing the contact area. With theiroutstanding chemical and creep resis-
tance,Vespel® seal rings are neitherattacked by hot oil nor extrudedbetween shaft and housing due topressure and heat.
Compared to other materials theassembly of Vespel® seal rings is easyand can be automated. The inherentflexibility of Vespel® makes seal ringseasy to open without breakage whileits toughness avoids deformationwhen inserting on the shaft.
With hydraulic pressure, seal ringswill then conform to the housing,without creeping, to provide sealing.
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Parts such as bushings, washersandthrust plugsworking in electricalmotors have to withstand axial andradial loads coupled with speed.
The wear and friction characteristicsof Vespel® have helped electricalmotor manufacturers to simplify theirdesign while improving performanceand life.
The search for comfort and safety in the automotive industry has lead toincreased numbers of electric motors.
These are now widely used to makedriving more pleasant (window lift,sunroof, central locking, air condi-tioning actuation, seat, mirrors & steering adjustment) and safer (windscreen wipers, idle and exhaustcontrols, differential locking).
Increasing regulations and specifica-tions for equipment such as starter-motors and fuel pumps place greaterdemands on mechanical wear andfriction components.
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VESPEL®
VESPEL®
EL
EC
TR
ICA
LM
OT
OR
S
BushingsUsed in all kinds of electrical motors,Vespel® bushings can run with orwithout lubrication depending on theapplication. A "straight" bushingdesign is adapted to radial loading buta "flanged" design can additionallybear axial loads and therefore elimi-nate the need for a washer.
Parts can easily be press-fitted intothe housing while maintaining verygood control of the inside diameter.In addition, the high PVcapabilityenables the length of the bushing tobe reduced.
In these types of application, a lowand constant coefficient of friction isrequired as well as wear and creepresistance.
The various Vespel® graphite filledgrades provide cost effective solutions.
plugs are parts that are directly fittedinto the rotor shaft with a slight interference.
Like washers, these parts have to takeaxial loads, and resist creep and wear.
Depending on the application, a lowor relatively high coefficient of fric-tion may be required, and unfilled SP1 or SP21 filled with graphite are the usual preferred choices.
During very severe use, Vespel® thrustplugs will not melt and thereforeguarantee the function.
WashersWashers take the axial load in electri-cal motors which means that whileproviding wear and friction resistanceas bushings do, they also have towithstand impact.
Due to the small loading area of suchcomponents, both pressure and veloc-ity conditions can be high, generatingexcessive frictional heat.
The creep resistance and the PVcapa-bility of Vespel® washers guaranteelong and reliable life of the equipment.
Noise, often generated by metallicparts running against each other, iseliminated.
Thrust plugsSpecifically used in windscreen wipers,window lift, sunroof, seat adjusting,differential lock motors, etc.,thrust
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Braking is the most important func-tion in a vehicle today and the mainemphasis is on safety.
Anti-lock braking systems regulatethe brake fluid pressure applied ateach wheel to avoid skidding andoptimize braking.
Wear pads are equipped with electricalsensors that detect when the liningmaterial is worn and alert drivers viaa light on the dashboard.
The properties of Vespel® enable it toresolve the technical problems in bothareas.
Anti-lock brakingsystemsUsed as valve components, (seats,balls) Vespel® parts provide excellentsealing due to their outstanding com-pressive behaviour. They also resisthigh impact and improve responsetime with their light weight.
Wear padsVespel® sensors are installed into themetallic support of brake pads. Thesensor insulates, both thermally andelectrically, the wire which connectsto a brake wear warning light.
Here the material has to provide alow and constant wear rate, withoutmelting; and without depositing anyfilm on the disc that would damage itby modifying the electrical contact.
VESPEL®
BR
AK
ES
Gasoline and diesel injection systemsrequire supply and injection pumps.Depending on fuel type and function,they have different working pressuresand designs, but all need wear andfriction and/or sealing components thatcan guarantee life and performance.
Vespel® has excellent chemical com-patibility with various types of fuelswithout excessive swelling, whichensures the success of Vespel® partssuch as bushings, seal rings, bandsprings and valve seats.
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Turbo chargers are characterized byvery high running speeds and hightemperatures. Turbo chargers aredevices where Vespel® can demon-strate its properties.
As ball bearing retainers, Vespel®
can improve response time of the turbocharger through low weight andinertia.
As wastegate bushings, Vespel® canprovide the required sealing withoutwear and abrasion of the shaft.
Similar benefits under these conditionshave been provenin Exhaust GasReturn (EGR) systems.
FUEL SYSTEMS
TURBO CHARGERS
Vespel® parts have a unique combina-tion of properties which has enabledthem to be used in a wide variety ofautomotive applications.
For example:
• Vacuum pump vaneswhere out-standing wear behaviour guaranteessealing without abrasion of housings,often in soft metal
• Engine belt tensionerswhich provide wear and friction character-istics while eliminating matingmaterial wear debris.
• Rubbing blocksin ignition distribu-tors to actuate breaker points, whichguarantee constant wear rate andresistance to vibrations at high temperature.
• Door hinge bushingswhich sur-vive paint oven temperatures andcleaning fluids while providing reli-ability of operation if there is anyloss of lubricant.
• Gear stick rollersfor automatic and manual transmissions whichhave low wear during intensive useconditions.
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VESPEL®
OT
HE
R E
QU
IPM
EN
T
Besides all applications describedpreviously, many other opportuni-ties can be seen for Vespel® in areassuch as:
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A
B
B
A
C
D
E
• Wheel disc nuts (B)• Steering systems (C)• Air conditioning (D)• Suspension systems (A)• High temperature engine
applications (E)
• Intake and exhaust systems (E)
• Piston rings (E)• Shock absorbers (A)
OP
PO
RTU
NIT
IES
15
Temp. Method Unit SP1 SP21 SP22 SP211 SP221 SP262Properties °C ASTM * *
Tensile strength, ultimate 23 D 1708 MPa 72.4 62 48.3 51.7 38.6 37.9260 36.5 30.3 26.2 24.1 19.3
Elongation, ultimate 23 D 1708 % 7.5 5.5 2.5 5.5 3.5 1260 7 5.2 2 5.3 0.7
Flexural strength, ultimate 23 D790 MPa 82.7 82.7 62.1 68.9 55.1260 44.8 48.3 37.9 34.5 31
Flexural modulus 23 D790 MPa 2482 3171 4826 2758 3445260 1448 1792 2758 1379 2205
Compressive strength 23 D695 MPaat 1 % strain 24.1 22.8 24.1 14.5 14.5 40at 10 % strain 112.4 104.8 93.8 75.8 78.6at 0.1 % offset 33.1 33.8 25.5 27.6
Impact strength, Izod, 23 D256 J/m 42.7 42.7notchedImpact strength, Izod, 747 320unnotched
Coefficient of frictionPV = 0.875 MPa.m/s 0.29 0.24 0.3 0.12 0.1PV = 3.5 MPa.m/s 0.12 0.09 0.08 0.05Max. PV MPa.m/s 12 10 3.6 3.6 12Wear rate at PV0.875 MPa.m/s m/s 10-10 17 - 85 6.3 4.2 4.9
Thermal conductivity 40 W/m.°C 0.29 0.46 0.89 0.42 2.53
Coefficient of linear µm/m.°C 50 41 27 41 26 13thermal expansion
Water absorption, D570 % 1.0 - 1.3 0.8 - 1.1equilibrium, 50% RH
Specific gravity D792 1.34 1.42 1.56 1.46 1.74
Deformation under load 50 D648 % 0.2 0.17 0.14 0.29 0.3
* Some values for the new compositions SP221 and SP262 are preliminary or have been extrapolated from initial test data .For more technical details related to the product compositions or to your typical application, refer to the Vespel® Design Handbook and con-tact your Local Sales Engineer.
Summary of typical properties of Vespel® SP polymide resins
VESPEL®
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Technical team • Handling your technical enquiries
• Assisting you with your developments
• Design & testing
• CAD, FEA
• New composition developments
Marketing team • Local qualified field engineers in
direct contact with customers
• Quoting in EU-currencies
• Wide knowledge of applications
• Product development support
Vespel® offer• Supply of finished parts
• Sites in USA, Japan and Europe
• Centralized services in Mechelen(Belgium)
• Quality ISO 9001
• Door-to-door delivery
• Tool design and parts production
• Machining services available
AMSTERDAM
BRUSSELS
LEUVEN
AACHENKÖLN
NAMUR
LUXEMBOURG
ZAVENTEM
MECHELEN
LIEGE
HASSELT
ANTWERPENGENT
E17
E19E1
9
E411
E411
E40
E313E17
E40
E40
CHARLEROI
PARIS
LILLE
KORTRIJK
BRUGGE
OOSTENDE
®
Requests for further information fromcountries not listed should be sent to:
Du Pont de Nemours (Belgium)Vespel® ProductsA. Spinoystraat 6B-2800 MechelenTel. ++32-15-44 10 11Fax: ++32-15-44 14 08
VespelOnly by DuPont
®
®
Printed in Switzerland H-00000 07/97
This information corresponds to our current knowledgeon the subject. It is offered solely to provide possiblesuggestions for your own experimentations. It is notintended, however, to substitute for any testing youmay need to conduct to determine for yourself thesuitability of our products for your particular purposes.This information may be subject to revision as newknowledge and experience become available. Since wecannot anticipate all variations in actual end-useconditions,DuPont makes no warranties and assumesno liability in connection with any use of this infor-mation. Nothing in this publication is to be consideredas a license to operate under or a recommendation toinfringe any patent right. Caution: Do not use in medicalapplications involving permanent implantation in thehuman body. For other medical applications, see"DuPont Medical Caution Statement", H-51459.