Plastics are widely becoming regular substitutes for metal in transmissions. GTP can work with material suppliers and OEM Engineers to develop an innovative plastic transmission component for heat, chemical resistance, lubrication and strength. Additives, fillers, and reinforcements can vary the properties of a plastic to provide superior dimensional, heat and creep performance to replace components traditionally made of metal with lighter, more efficient plastic components.
Transmission and driveline related components are areas of growing interest for metal-to-plastic conversion initiatives. GTP has seen our business in this segment increase, and in conjunction, our knowledge base to develop and produce Baffles, Covers and other internal transmission components.
Transmission Baffles have traditionally been designed and manufactured from multiple metal stampings and weldments with an over molded seal. These complex assemblies require several manufacturing processes, special tooling and frequently represent quality issues. Additionally, Baffles are fully immersed in working fluids at high operating temperatures which has traditionally limited the application of polymers for these parts and also caused the over molded seal to become brittle and fail over time.
GTP’s engineering and materials group worked with OEM Engineers and specialty resin suppliers to develop a component capable of meeting all performance requirements, reduce labor build cost and provide improved chemical resistance, creep and cost. GTP developed a single piece molded Baffle complete with thin wipers to replace the over molded seal that scavenges transmission oil from the main transmission shaft. GTP also developed the use of light-weight, high tensile aluminum captured fasteners to further reduce mass and allow the customer to simplify assembly operations for additional cost savings. The end result was a weight savings of 85% and cast savings of 35%.