UNDER THE HOOD | AUTOMOTIVE
existing cooling line design and material solutions to their limits, narrowing the safety margin,” says Andreas Lutz, European Area Development Man- ager for Solvay’s Specialty Polymers global business unit. “Engine downsizing along with the generalisa- tion of high-temperature components such as turbochargers, superchargers, automatic transmis- sions, air conditioning and exhaust gas recirculation systems all crowded into a shrinking engine bay are leading to a ‘space crunch’ with hot spots that can exceed the thermal performance of conventional metal/rubber and polyamide designs.” The company adds that because coolant lines are among the last components to be designed to fit the engine bay, materials must not only offer the design freedom to enable more complex routing, but also provide enhanced thermal and chemical resistance to ensure operational safety without adding weight, such as the need for additional heat shields. PolyOne has rebranded ElectriPlast material technology as Surround EMI/RFI Shielding Formu- lations. This portfolio of conductive thermoplastic materials shields sensitive electronics from both electromagnetic interference (EMI) and radio frequency interference (RFI). Surround weighs up to 60% less than aluminium or copper, and brings increased design freedom compared with metal. The company says that Surround long fibre material is well suited to housings for advanced driver assistance systems (ADAS) because of its capability to replace metal in shielding applica- tions. As automakers continue to add ADAS functionality to automobiles, more electronic control units (ECUs), cameras, and sensors are needed to make the systems function properly. In addition to minimising cross talk between electron- ic components, Surround material is lighter weight and easier to process than traditional materials such as aluminium or copper. Injection moulding also permits more complex shapes and fewer design constraints than aluminium or copper, all
without compromising on dimensional stability of the component during use. Vehicle lightweighting continues to be a primary
trend and a catalyst for developing new materials for under-the-hood applications for injection moulders, according to carbon black producer Cabot Corporation. “Automotive OEMs are still targeting a higher share of plastics per car, and this applies for power train systems in both internal combustion engines and EVs,” says Dominique Strassler, Global Marketing Segment Manager. “However, for EVs the additional weight of the battery of around 200 kg is an additional consid-
eration. Reduced weight helps to comply with CO2 regulations, but also enables weight to be allocat- ed for gadgets and new technology systems. For EVs, thermal management is also a key topic, because the battery runs optimally at a certain temperature - not too hot and not too cold. Materials that can provide thermal conductivity, either combined with electrical conductivity or specifically without it, will be in higher demand. The trend toward plastics recycling is also highly relevant. Automotive OEMs look at this from two perspectives. Firstly, whether materials and plastics that are used in cars can be recycled later, and secondly whether automotive parts can be made out of these recycled materials.” There are also some specific technical areas of
interest at present requiring new solutions. “The industry has focused on lightweighting for a long time and, in general, lower density materials that are stronger and more durable are bringing incremental change,” Strassler adds. “Thermal management is mainly addressed by thermally conductive solutions. In the plastics world, this is an area that still has lots of room for new develop- ments. While metal has unique properties, it is prone to corrosion which is a disadvantage when compared to plastics. Regarding recycling, one topic is sortability, which puts some constraints on
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