DSM Engineering Plastics

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Material solutions offer engineers design flexibility while reducing complexity

3 October 2019
  • Amit TolaniBusiness Development Manager

  • Russell BloomfieldGeneral Technical Service Engineer

In the automotive industry there is an increased demand for powertrains to deliver better fuel economy, higher efficiency, and reduce emissions. The trend to improve engine efficiency with better fuel economy and an increase in engine power owes a lot to turbocharge technology. Increase in engine performance and efficiency results in high heat and more aggressive gasses often under high pressure.

Air Management Systems, such as air ducts, turbo charger hoses, and seals are expected to withstand these high temperatures up to 250°C peak. Metals such as aluminums and certain types of rubbers can withstand these hot temperatures, but the design associated with these materials often incorporate higher weight, complex processing parameters, and multiple part numbers. They are either eco-neutral or non-eco-friendly materials. So, the challenge lies in the metal and rubber materials that may offer performance but not design flexibility nor simplicity during the assembly process.

This material raises the performance benchmark of temperature resistant TPCs that provide:

  • Improved heat resistance
  • Flexibility to cover engine movements in a single part solution
  • Reduced weight compared to rubber and metal
  • Single blow/injection molded TPC solution

One Arnitel HT application is the 3D suction blow molded hot charge air duct for the 2019 Cadillac XT4. The material was recognized as this year’s runner-up for innovation in the Enabling Technology category during the 2019 Altair Enlighten Awards.

The Arnitel duct replaced a thermoset rubber hose and rigid plastic hybrid assembly, significantly reducing the weight, cost, and design complexity of the vehicle’s turbocharger system. The nomination recognized the combined efforts of DSM, General Motors, Cikautxo Group, and HENN GmbH & Co KG. To read more about the award and material solutions application visit: Arnitel hot charge air duct recognized during 2019 Altair Enlighten Awards.

The ideal air duct

A material solution that can withstand high temperatures and take vibrations, is compatible with the environment, helps reduce the weight of the engine, and is ecofriendly is the ideal material that can help engineers overcome the design challenges often faced when working with metal and rubber materials. High temperature TPCs (thermoplastic copolyester) from DSM 

set new standards in high temperature flexible air duct applications.

The Arnitel HT advanced engineered TPCs expand the temperature capability of traditional TPC by offering up to 190°C peak and 175°C operating temperature capability—well beyond the capability of TPC materials that are traditionally positioned for air duct applications.

This material offers long-term heat aging performance and robust chemical resistance; therefore, high temperature ducts can be made from a single material solution. By using one material there is less potential for leakage because of less parts and connection areas.

A single material solution also makes it easier and faster to process, equating to a system cost advantage and weight reduction up to 50 percent. Arnitel HT also offers flexibility and mechanics even at low temperature.

Another ideal material solution

Stanyl Diablo OCD 2305 BM is another blow moldable solution that can handle continuous use temperatures up to 230°C. It offers a weight reduction up to 10% vs PPS and up to 30% vs aluminum, along with improved toughness, peak temperature capability, and superior strength-at-temperature as compared to traditionally available PA66-based blow moldable materials.

After heat aging, it has robust elongation retention. Plus, it has a proven chemical resistance to EGR and blow by condensate. Stanyl PA46 retains mechanical properties at high temperatures, making it ideal for duct applications. It suffers modest loss in mechanical performance after 3,000 hours heat aging.

Both these material solutions offer weight reduction, proven performance, and cost effectiveness. Also, grades with higher strength can be used to reduce wall thickness and therefore also save further weight in some applications.

To learn more about Arnitel HT and Stanyl Diablo OCD 2305 BM, or to request test samples, contact us or visit plasticsfinder.com for additional information, including technical data sheets.

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