| Description |
|
Transmission Thrust Washer |
| OEM, Model, Model Year |
|
Ford, F-Series Super Duty , 1999 |
| System Supplier, Contact, Phone |
|
Ford Powertrain, Fredrick Gerometta, (734)523-3074 |
| Molder/Processor, Contact and Phone |
|
LDM Technologies, Dan Evans, (248)858-2800 |
| Toolmaker |
|
Michian Plastics |
| Material Supplier, Contact and Phone |
|
Mitsui Chemicals, Inc., Marianne Morgan, (248)377-2647 |
| Generic resin type |
|
Thermoplastic Polyimide |
| Resin Trade Name |
|
AURUM |
| Grade |
|
JCL 3030 |
| OEM Engineer, Title and Phone |
|
Fredrick T. Gerometta, Product Design Engineer, (734)523-3074 |
| Nominated by, Company |
|
Marianne Morgan/Dan Evans , Mitsui Chemicals/LDM Technologies |
| Address |
|
1787 Snowden Circle, Rochester Hills, MI 48306 |
| Phone |
|
(248)377-2647 |
| Fax |
|
(248)377-0434 |
| Email |
|
msmorgan1@aol.com |
| Summary | | First multi-platform commercial use of a high performance thermoplastic in the torque converter, the hottest and most demanding section of a transmission where previously only thermosets and metals had been utilized. The washer's thickness is only 1.5mm, a 50% reduction vs a needle thrust bearing. This freed up critical packaging space as to design a more robust piston for higher durability applications. Weight Savings: 28 grams Cost Savings: 35% cost reduction vs a needle thrust bearing. |
| Most Innovative Feature | | This application represents the first multi-platform commercial use of a high performance thermoplastic in the torque converter, the hottest and most demanding section of a transmission where previously only thermosets and metals had been utilized. |
| Other Innovative Features | | The washer's thickness is only 1.5mm, a 50% reduction vs a needle thrust bearing. This freed up critical packaging space as to design a more robust piston for higher durability applications. |
| Forming Process | | Injection molding using standard equipment. |
| First time process used? | | Thermoplastics had previously not been used in this area of the transmission due to the demanding environment consisting of high heat, pressure, and velocity. |
| Previous Process Used | | Thermosets and Metallics |
| Tooling Innovations | | No special tooling required. Standard injection molding equipment is used and so no special capital equipment investment was needed. |
| New Material Developments | | The thermoplastic polyimide was reinforced with carbon fibers and was internally lubricated for enhance tribological performance. |
| Weight Savings | | The specific gravity of the thermoplastic resin is 4.5X lighter than steel. The estimated weight reduction is at 28 g. |
| Direct Cost Savings | | The thermoplastic polyimide thrust washer was a 35% cost reduction as compared a needle thrust bearing alternative design. |
| Indirect Cost Savings | | Avoided re-engineering and design changes when the torque was mated to higher load transmissions. |
| Direct Consumer Benefit | | Allowed the higher engine house power. |
| Translates to other Vehicles? | | Yes |
| Safety Benefits | | none noted |
| Environmental Benefits | | The thermoplastic polyimide is fully recyclable and reusable |
| Additional Info | | The AURUM thrust washer is slated to be used on a future transmission torque converter beginning in 2003. It is currently used on the 4R100 transmission. |