automotive | Under-the-hood
Right: Sche- matic of the
polymer-based Polimotor 2
engine concept by Solvay
Solvay says it will replace up to ten metal engine components – in- cluding the water pump, oil pump, water inlet/outlet, throttle body, fuel rail, cam sprockets and others – with parts made from seven of its high perfor-
mance thermoplastics. These include not only Torlon, but also Amodel polyphthalamide, KetaSpire and AvaSpire
polyaryletherketones, Radel polyphe- nylsulphone, and Ryton polyphenylene sulphide. Material options for the engine
block, oil pan, cam block and other components are currently being evaluated, Solvay adds.
Solvay says Polimotor 2 will utilise multiple manu-
facturing technologies including injection moulding, compression moulding, machining, and additive manufacturing. It says it is working to develop new applications that are not made in polymers today. “Light-weighting in the form of metal-to-plastic
replacement is one of the key enablers to reducing fuel consumption and thereby reducing CO2
emissions. The Polimotor 2 provides car makers with the opportunity to
light-weight their engines and can also be considered for hybrid vehicles as a range extender,” the company says. The Polimotor is an extreme example of how plastics
can be put to use under the bonnet, and it is diffi cult to imagine all of the applications it will incorporate going mainstream any time soon, if at all. But rather like the NASA space program, it will most likely provide traction for more commercially-realistic developments. Certainly demand for thermoplastics with high thermal stability for use under the bonnet in affordable family vehicles continues to rise. Technologies from major polyamide suppliers such as DSM, BASF and Lanxess for getting more heat resistance out of “standard” polymers (6, 66, and also, in DSM’s case, 46), have been discussed in recent issues of Injection World. But they are not alone in that area.
Invista Engineering Polymer Solutions, which specializes in PA66 compounds, has developed a high-temperature resistant PA66 for powertrain systems. It says its Torzen Marathon technology offers
improved long-term heat-ageing over conventional PA66, while also delivering the same balance of toughness, wear resistance and chemical resistance for which the resin is known.
The Invista technology does this by providing an added layer of surface protection compared to conventional PA66, allowing parts to retain strength even after exposure to
intense heat. There is a patent application pending on the technology, although at fi rst sight the concept appears similar to DSM’s Diablo and others. “Torzen Marathon PA66 resins are engineered to
withstand temperatures up to 230°C, retaining 50% tensile strength up to 1,000 hours,” Invista says. “The same resin exhibits 50% property retention at 190°C for 3,000 hours.” Traditional PA66 is normally suitable for temperatures up to 180°C. Torzen Marathon is aimed at parts such as the charge air cooler, air ducts, resonators, and other integrated parts related to the turbo system. Invista says that, in addition to high-temperature
resistance, Torzen Marathon resins offer improved processing characteristics. “We have seen as much as 30% pressure reduction when using Torzen Marathon resins,” a representative says.
Targeting safety
A little higher up the temperature resistance ladder, EMS-Grivory offers Grivory HT2VS-HH, a heat stabi- lised, glass reinforced range of its Grivory HT2 PA6T/66 polyphthalamide (itself a high heat polyamide).
Introduced at the K show in 2013, the company says the fi rst applications for the grade – which uses a surface protection technology to provide additional thermal resistance - are now showing convincing results. It cites an emergency gear release for the Audi Q7, produced by Dura Automotive Systems, which relies on Grivory HT2VS-3HH (the 3 indicates 30% reinforcement). The emergency release system is located very close to the engine and is needed when, for example, the car battery is fl at, the electronic systems fail or the
car key has been lost and the drive lever
Emergency gear release for the Audi Q7 in Grivory HT2VS-3HH
14 INJECTION WORLD | June 2015 is blocked in the “park” position. EMS-Grivory says that, as part of an emergency
www.injectionworld.com
PHOTO: EMS GRIVORY
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