Ultramid® AB polyamide material of choice in the Grand Award Winner - Ford Motor Company's diesel exhaust fluid (DEF) system
WYANDOTTE, MI, - The Society of Plastics Engineers International (SPE®) held its 40th Annual Automotive Innovation Awards Gala at Burton Manor in Livonia, Michigan last week. More than 50 parts were entered in the competition and BASF received the overall SPE Innovation Grand Award for Ultramid AE3G7 AB, which also won the Powertrain category.
In addition, BASF placed as a finalist in four other category submissions, including Materials, Enabling Technologies, Chassis and Powertrain.
Grand Award and Powertrain category winner The SPE Innovation Grand prize, awarded to Ford Motor Company for their Diesel-Exhaust Fluid (DEF) System submission, is the first high-volume pickup truck application to use an all-plastic system to fill, store and deliver DEF to the exhaust system to meet stringent diesel-emissions requirements. BASF's Ultramid AE3G7 AB grade was specially developed for use in diesel exhaust treatment systems that use urea. Resins in contact with AdBlue, a urea/distilled water solution, need to be ultra pure, especially relative to metal contaminate, as contaminates are extracted into the solution and reduce the effectiveness of the down stream catalysis. This resin is a PA 6,6 colored, 35 percent glass reinforced grade. The level sensor and urea reservoir were manufactured using Ultramid AB, while the supply module lid is manufactured using Ultramid B resin. Finalists All night, BASF continued to validate the performance of plastics in engine compartments. For its all-new 2010 Jeep® Grand Cherokee, Chrysler developed a thermoplastic oil pan module for the 5.7L Hemi engine. MAHLE North America, the tier supplier, created the module incorporating the oil pan, pickup tube, windage tray with a cam scraper function, oil plug, gasket and bolts, thereby reducing weight, labor and assembly costs. This is the first oil pan that is a true module with multiple part integration.
To meet Chrysler's trail rating requirement, the vehicle must climb at a 60 percent grade (31-degree incline) without losing performance. As difficult as a 31 degree slope is, this vehicle's 5.7L engine already sits at a 7 degree angle resulting in a 38 degree slope to conquer. Without oil in the sump, the engine would fail.
The challenge of "moving oil uphill" to the sump was met by molding oil channels in the pan and welding the windage tray over the top to create a seal. Then, the returning oil from the engine is forced up these channels to the sump. BASF's polyamide material, Ultramid B3ZB7 OSI, a high-impact modified PA6, 35 percent glass reinforced resin specifically designed for oil pans exposed to stone impact and road salt, met Chrysler's requirements for an all plastic oil pan.
In the Chassis Hardware category, the ContiTech transmission cross beam manufactured of plastic polyamide and used in the new BMW 5 Series Gran Turismo 550i placed as a finalist in this category. For the first time, by choosing Ultramid A3WG10 CR instead of aluminum, it was possible to reduce the weight of the part by 50 percent. The cross beam was developed by ContiTech Vibration Control in close cooperation with BMW and BASF.
Chrysler's cylinder head cover, entered into the Process, Assembly and Enabling Technologies category, was also named a finalist. Bruss of North America was able to achieve extraordinary injection molded part tolerances enabling the continued use of a light-weight composite while incorporating the variable valve timing function into a thermoplastic cover. The material development for this application was a PA 6,6 35 percent glass reinforced high productive grade, Ultramid A3WG7 HP. In addition to the high flow feature, this resin has an attractive surface appearance that is important to the quality image of the engine.
A finalist in the Material category went to BASF's new Ultramid® A3WG7 HRX, a PA 6,6 35 percent glass filled hydrolysis resistant grade resin with excellent physical property retention at a continuous temperature of 130 degrees Celsius. These properties contributed to the success of Hengst of North America's innovative oil filter cooling module design in the Chrysler Pentastar® V6 engine. The newly launched Pentastar® engine design, anticipated to be used in 40 percent of Chrysler engines by 2014, delivers several innovations in engine technology that brings both higher power and better fuel economy.
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BRUSS - The Sealing System Company
Bruss North America Inc. headquartered In Russell Springs, Ky. is the North American affiliate of Dichtungstechnik G. BRUSS GMBH & CO. KG Hoisdorf, Germany. For more information about the Bruss Company visit our web site at www.bruss.de.
Bruss is a global leader in developing and manufacturing of high-performance sealing systems for powertrain applications. Automobile manufacturers throughout the world have relied on our seals, gaskets and modules for over 50 years. Taking our experience and technical expertise as a basis, we develop products that are specially tailored to meet our Customers needs. This makes Bruss an innovative specialist in providing individual problem solutions in the area of sealing technology.
ContiTech AG, Hanover, is the world's largest specialist for rubber and plastics technology in the non-tire rubber sector. The company develops and produces functional parts, components and systems for the automotive industry and other key industries. It has a workforce of around 21,000. In 2008, it posted sales in the order of Euros3 billion. ContiTech is a division of Continental AG, one of the world's major automotive suppliers, with sales of more than Euros24 billion in 2008. As a supplier of brake systems, systems and components for the powertrain and chassis, instrumentation, infotainment solutions, vehicle electronics, tires, and technical elastomers, the corporation contributes to enhanced driving safety and global climate protection. Continental is also a competent partner in networked automobile communication. The corporation currently employs approximately 134,000 at nearly 190 locations in 35 countries.
The MAHLE Group
The MAHLE Group is one of the 30 largest companies in the automotive supply industry worldwide. As a leading manufacturer of components and systems for the combustion engine and related products, MAHLE ranks among the top 3 systems suppliers for piston systems, cylinder components, valve train systems, air management systems, and liquid management systems. In 2008, MAHLE employed around 45,000 people at over 100 production plants and eight research and development centers and achieved sales of over 5 billion euros. More information at www.mahle.com
BASF - The Chemical Company
BASF Corporation, headquartered in Florham Park, New Jersey, is the North American affiliate of BASF SE, Ludwigshafen, Germany. BASF has approximately 16,000 employees in North America, and had sales of $13 billion in 2009. For more information about BASF's North American operations, or to sign up to receive news releases by e-mail, visit www.basf.us.
BASF is the world's leading chemical company: The Chemical Company. Its portfolio ranges from chemicals, plastics and performance products to agricultural products, fine chemicals and oil and gas. As a reliable partner, BASF creates chemistry to help its customers in virtually all industries to be more successful. With its high-value products and intelligent solutions, BASF plays an important role in finding answers to global challenges, such as climate protection, energy efficiency, nutrition and mobility. BASF posted sales of more than Euros50 billion in 2009 and had approximately 105,000 employees as of the end of the year. Further information on BASF is available on the Internet at www.basf.com.