Tata Toyo adopts DuPont™ Zytel® PLUS nylon for added durability in charge air coolers

Charge Air Coolers | DuPont™ Zytel®

Tata Toyo has selected DuPont Zytel® PLUS nylon for three hot- and cold-side charge air coolers on turbo-diesel engines powering four passenger, utility and light commercial vehicle models produced by a major Indian auto OEM.

Zytel® was chosen for easy processing and added resistance to heat, chemicals and pressure, in replacement of a specialty nylon resin product. Tata Toyo, a leading heat-exchange technology supplier based in Pune, India, is now looking to replace metals with Zytel® in other applications.

Improving powertrain efficiency

Charge air coolers quickly cool hot air generated by the turbocharger before it is forced through the induction system. Cooler air improves combustion efficiency.

"Improving powertrain efficiency while reducing weight and cost is critical to improving fuel economy and reducing dependence on fossil fuels," said Patrick Ferronato, director of automotive, DuPont Performance Polymers. "Turbo systems are one of several technologies the industry is quickly adopting to boost the performance of smaller, more efficient engines. The environment these power-boost technologies create is challenging the capabilities of many existing engineering thermoplastics."

Zytel® PLUS for long-term resistance

Last year DuPont introduced the Zytel® PLUS family of high-performance nylon and PPA materials that deliver long-term resistance to heat, chemicals and pressure. Unlike specialty nylon resins, Zytel® PLUS retains processing ease typical of traditional nylon resins. This family is targeted primarily at automotive underhood and engine applications.

Zytel® PLUS nylon was selected to replace the specialty nylon because it retains rigidity at high temperatures, offers a better surface appearance and processes with ease. "We enjoy a long-term relationship with Tata Toyo," said Avinash Malshe, industry manager, DuPont Performance Polymers Automotive – India. "When we introduced them to the new materials, they quickly saw the chance to think about where they can use them to deliver better performance and cost. While collaborating, we found more opportunities to capture significant weight savings by replacing metal components and systems."

Collaborating is critical to fast adoption of new technologies that reduce dependence on fossil fuels. DuPont has invested in several new collaboration facilities, including the India Innovation Center in Pune, India. The facility is focused primarily on the automotive segment with a goal of connecting globally on materials and solutions that improve sustainability, performance, safety, comfort and design, while reducing weight and enabling alternative-drive vehicle systems.

More than 1,700 new products

Last year DuPont launched more than 1,700 new products and invested 22 percent of its $1.7 billion R&D budget on developing new chemistry and materials to reduce dependence on fossil fuels.

DuPont offers more than 100 materials and product families for the global automotive industry. Through its global application development network, DuPont Automotive is committed to collaborating with customers throughout the value chain to develop new products, materials, components and systems that help reduce dependence on fossil fuels and protect people and the environment.