1. editorialDuPont Engineering Polymers is
committed to providing customers
with highly innovative, cost
effective and environmentally
sustainable solutions. Our success
isrootedinourabilitytodevelop
materialanddesignsolutionswith
customers, then support them
globally in moving rapidly from
concepttocommercialization.
Wehavesuccessfullyhelpedour
customers replace metal and
other materials to achieve more
cost efficient and more environ-
mentally sustainable solutions
with our portfolio of high perform-
ance engineering polymers and
state-of-the-artdesignconcepts.
With this issue of Engineering
Design we are introducing
DuPont™
ETPV engineering
thermoplastic vulcanizates
worldwide in line with the
product’s official October 2004
launch at the K’04 show in
Düsseldorf,Germany.
In the tradition of historic
polymer breakthroughs like
nylon and Kevlar®
, the ETPV
product family was developed at
our Experimental Station in
Wilmington Delaware, USA. And
like all the best DuPont
inventions,itisaworldfirst.
First in that DuPont™
ETPVs have
all the best properties of high
performance cross-linked rubbers
– plus all the customer benefits
of DuPont thermoplastics.
DuPont™
ETPV is an outstanding
replacement for high perform-
ance cross-linked rubbers,
processable on equipment that
DuPont Engineering Polymers
customers have already installed,
andwithwhichtheyarefamiliar.
DuPont™
ETPV is a very flexible
thermoplastic material in the
ShoreArange(mostthermoplastic
elastomers qualify for Shore D)
that resists temperatures higher
than 150 degrees C in air for 3,000
hours in combination with
excellent oil resistance. DuPont™
ETPV was developed to provide
our customers with significantly
improved rubber replacement
solutions. The DuPont™
ETPV
productfamilyeffectivelybroadens
ourrangeofinnovativesolutionsin
high performance flexible
thermoplasticpolymers.
DuPont™
ETPV delivers the bene-
fits of high performance thermo-
set rubbers – but with sub-
stantial processing cost savings
comparedwiththermosets. Like
other thermoplastics, DuPont™
ETPV has a wide processing
window and can be injection
moulded, 2K injection moulded,
extrudedorblowmoulded.
As an essential plus, the
thermoplastic manufacturing
process is very robust and
produces parts with high and
consistent quality. The process-
ing is also ‘cleaner’ than with
rubbers and, like other thermo-
plastics, waste can be recycled,
making for a product that helps
our customers in the goal of
environmentally sustainable
manufacturing.
Our customers have been telling
us that they want a product with
all the properties of high perform-
ance cross-linked rubber – but
processable at a lower cost, with
less waste and with more
consistent quality. Here is that
product! The new DuPont™
ETPV
product range enables DuPont
Engineering Polymers custo-
mers to expand their businesses
in targeting the replacement of
high performance cross-linked
rubber in under-the-hood auto-
motive applications such as
hoses, seals and gaskets,
ignition coil boots and body
plugs. Some of our first success
stories are highlighted in the
followingpages.
As a next step, we will work with
customers to bring the outstand-
ing properties of DuPont™
ETPV
to other market sectors such as
industrial equipment, electrical
and electronic applications and
DuPont
™
ETPV: the thermoplastic rubber that resists
‘‘DuPont™
ETPVisa
veryflexible
thermoplasticmaterial
intheShoreArange
thatresists
temperatureshigher
than150°Cinairfor
3,000hoursin
combinationwith
excellentoil
resistance.’’
OrvarOtterstedt
DuPontEngineeringPolymers
ETPVglobalmarketingmanager
ED 02.04 10/1/04 11:30 Page 2

2. appliances in all areas where
customersrequiretheproperties
of high performance cross linked
rubberswithreducedprocessing
costs, more consistent quality
andnowaste.
What’s even more exciting is that
we’rejustbeginningtoexplorethe
possibilities of this new DuPont
invention. We were very pleased,
for example, at the outstanding
heat ageing performance of
DuPont™
ETPV shown in recently
published Arrhenius curves - a
powerful tool to determine the
long ageing or heat properties of
polymermaterials.
One thing is for sure: the potential
growthmarketforDuPont™
ETPVis
significant – and its applications
are limited only by the
imaginations of Engineering
Designreaders.
OrvarOtterstedt
DuPontEngineeringPolymers
ETPVglobalmarketingmanager
hat resists oil and heat 4
5
8
11
14
16
18
DuPont™
ETPV: the thermoplastic rubber
that resists oil and heat. "Our customers
have been telling us that they want a
product with all the properties of cross-
linked rubber – but processable at a lower
cost, with less waste and with more
consistentquality. Hereisthatproduct!"
Working safely. The Procap integrated
respiratory protection helmet, welding shield
and visor frame are all made of DuPont™
Zytel®
ST, selected for its light weight, impact
resistanceandoveralloutstandingmechanical
resistanceathighandlowtemperatures.
Catching the telematics wave. The
automotive industry is gearing up for
telematics growth in tyre pressure
monitoring, satellite radio and TV,
global positioning and more using
Zytel®
HTN, Zytel®
and Delrin®
.
Formula One ... on water. Relying on
advanced DuPont materials and technical
assistance for 21 key components, Mercury
Marine engineers have achieved break-
through performance in Verado water-
boundoutboardengines.
Fuel savings for Toyota. The world’s first
‘waterjacketspacer’foropendeckenginesfor
the2004modelofToyota’sluxuryZeroCrown
car is made of DuPont™
Zytel®
HTN. It brings
substantial fuel savings , confirming Toyota’s
commitment to the production of environ-
mentally-acceptable vehicles.
Cleaner air. Exhaust-gas return (EGR)
systemsgreatlyreducethequantityofharmful
nitrogen oxides that internal combustion mo-
torsproduce.TheuseofDuPont™
Vespel®
poly-
imide parts and DuPont™
Zenite®
LCP contri-
bute to the reliable operation of these valves
under extreme under-the-hood conditions.
New Ford roof rack can take more load.
A roof rack system for the new Ford
Territory multi-purpose activity vehicle
provides surprisingly positive steps
forward in functionality thanks to the
extensiveuseofDuPont™
Zytel®
andDelrin®
.
contents
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