Zytel^® NVH Gen 2 Makes Electric Vehicles Even Quieter

DÜSSELDORF. Oct. 12, 2022 – Most cars still use metal for structural chassis and suspension system applications. Replacing that metal with DuPont's newly formulated PA66 material, Zytel^® NVH Gen 2, offers a host of compelling improvements. This lighter-weight, next-generation composite technology gives drivers and passengers a superior driving experience by controlling noise and vibration more effectively than metal.

Electric vehicles (EVs) pose unique challenges when it comes to isolating structure-borne noise and vibration originating from their electric drive units. Without the relatively loud internal combustion engine masking them, these noises become much more apparent. It’s a complex issue involving vehicle safety and passenger comfort, while engineers find it difficult to point to a single part or component that is the root cause of the noise.

To meet these challenges, the automotive electrification team at DuPont developed Zytel^® NVH70G35HSLA2, the first entry in the Zytel^® NVH Gen 2 product family. This innovative PA66-based, 35% glass-filled polymer offers high damping, yet keeps its base polymer’s robust structural properties for parts that need sustained mechanical strength throughout their lifecycles.

“This new Zytel^® grade takes a different approach to high-frequency vibration isolation by utilizing the material’s structural damping ability without sacrificing extended fatigue resistance over time,” explained Gabe Knee, Automotive Market Manager, DuPont. “We’ve created a cost-efficient, mass-saving, and tunable solution for electric drive units that mitigates NVH problems in electric vehicles, making them even quieter and more comfortable.”

The material can endure high-stress conditions and provide stable characteristics under varying ambient and loading conditions.

In a recent commercial application in North America involving EV motor mounts, Zytel^® NVH Gen 2 maintained structural integrity while offering over 20% direct mass savings and considerable material cost savings compared to aluminum. With these mounts, designers were able to tune, mitigate, or eliminate irritating harmonics that would otherwise be transmitted and detected by drivers and passengers in the cabin.

“With our design and prototyping capabilities,” adds Knee, “we help customers identify problematic component designs that are contributing to NVH issues, then help create the solution for managing them.”

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DuPont Mobility & Materials invites visitors to K 2022 to its exhibit area in Hall 6, Stand C43 from October 19-26, to see the latest in sustainable and transformative materials.

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About DuPont Mobility & Materials  

DuPont Mobility & Materials (M&M) delivers a broad range of technology-based products and solutions to the automotive, electronics, industrial, consumer, medical, photovoltaic, and telecom markets. DuPont M&M partners with customers to drive innovation by utilizing its expertise and knowledge in polymer and materials science. DuPont M&M works with customers throughout the value chain to enable material systems solutions for demanding applications and environments. 

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