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Sound Modelling Resonator...

DuPont™ Zytel® PLUS 95G35 is a high-performance polyamide, produced with DuPont’s proprietary SHIELD technology which provides superior long-term resistance to high temperature and aggressive fluids making it ideal for the resonator on the BMW i8 plug-in hybrid sports car.  The material is tuned to reduce the typical high-frequency air intake sound to a lower level, so improving the driving experience.

Due to its function, the resonator has a relatively large volume, but – thanks to an optimized design in terms of wall thicknesses and the use of this high stiffness and high strength grade of Zytel® PLUS – it weighs just 1.5 kg. Installed between the air filter and turbo charger in the rear of the i8, it is part of the air management system of the sports car’s compact 1.5 liter 3-cylinder petrol engine.

Due to Zytel® PLUS, the resonator has long-term resistance to temperatures from -40°C to 190°C as well as hot engine gases and fluids. Due to the close proximity to the exhaust gas system and direct contact with chemicals such as road salt, standard polyamide materials were ruled out for this demanding application due to their insufficient long-term heat and chemical resistance. Zytel® PLUS 95G35 performs well in such a hot and confined operating environment and what’s more, it retains most of its weld strength even after extended exposure to very high temperatures, where traditional materials would drop significantly.


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