Flexible PPS Fasteners for High Heat Applications

This first time application allows plastic (PPS – Polyphenyline Sulfide) to replace metal and/or shielded nylon in high heat fastener applications. A 50% weight savings was achieved via elimination of metal fasteners and the elimination of shielding with a cost savings of over $20,000. Flexibility was maintained after high-heat exposure without shielding and assembly and ergonomics were improved. This technology is transferrable to many high-heat harness applications underhood or near the exhaust.

OEM/Vehicle Ford Motor Company 2018 Ford F150 System Supplier Lear Corporation Material Processor    HellermannTyton

Material Supplier Celanese Resin Fortron FX72T6 PPS

For More Information See: http://www.plastics-car.com/Resources/Resource-Library

PVC Vent Tube

Increased temperatures due to engine downsizing and turbo boosting required the development of a new material with thermal performance to 175C for the crankcase ventilation tube. Additionally, the team wanted to eliminate metal and rubber parts but retain the flexibility to use quick connectors to the engine during final assembly. A flexible alloy based on unreinforced, impact modified PPS was selected. Parts are formed by reactive extrusion followed by thermoforming at 190C for 25 minutes. They are 50% lighter than. metal and save $3/part. They also offer better temperature and resistance than previous PA 6 tubes.

OEM/Vehicle General Motors Co. 2016 LGE Platform System Supplier Chinaust Group Material Processor    Chinaust Group

Material Supplier Celanese Corp. Resin Fortron FX75T1 PPS

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains/Drive-Shaft.html

Air Induction System Mounting Structure

This air-induction system mounting structure replaced a steel part that was very complex and challenging to manufacture with an injection molded PPS/PA part. The plastic mounting system reduced mass 68%, eliminated an anti-corrosion coating, reduced production costs 64% and brought tooling savings of 50% vs. the previous steel part. Additionally, the polymer part met all application requirements for thermal stability, chemical resistance, dimensional stability, fatigue resistance, and stiffness.

OEM/Vehicle General Motors Co. 2016 Chevrolet Malibu System Supplier Toledo Molding and Die, Inc. Material Processor    Toledo Molding and Die, Inc.

Material Supplier Solvay Specialty Polymers Resin Ryton XK2340 PPS/PA Tooling/Equipment Supplier Toledo Molding and Die, Inc.

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior/Instrument-Panels.html

Injection/Blow Molded Intercooler Air Duct

This is the first time glass-reinforced PPS has successfully been blow molded. The complex part was formed by a unique patented hybrid injection/blow-molding process, which allows functional elements to be injected against the parison during expansion, forming a chemical bond and yielding a robust part with a clean joint vs. welding the element to the part in a secondary step. Two different grades of glass-reinforced PPS were used. The process eliminates two previous production steps and provides extremely high repeat accuracy. High-performance PPS resin provides dimensional stability and outstanding mechanicals in high-temperature, chemically aggressive environments at cost and weight reductions.

OEM/Vehicle 2008MY Volkswagen AG: Volkswagen® PQ35 Platform System Supplier Röchling Automotive Leifers GmbH

Material Supplier Ticona Engineering Polymers Resin Fortron® 1115L0 PPS

For More Information See: http://www.plastics-car.com/airducts

Plastic Transmission Accumulator Piston

This molded plastic transmission accumulator piston was designed around the current application so that the bore, seal rings, and return springs did not have to be changed and it was a drop-in replacement.  Maximum effort went into material choice (PPS) and model shape to achieve appropriate toughness to handle time, temperature, pressure, and combined cycling to create a 200,000-mile capable piston.  The resulting part is 29 g vs. typical 47 g for aluminum pistons.  A direct thermoplastic injection technology was developed to produce the parts, resulting in zero material waste through the use of a single-cavity design.  The process allowed for a 33% improvement in cycle times and reduce the total floor space required by 20% over previous multi-cavity processes. The innovative approach used here has allowed for a modular business cell that is adaptable to large market-volume fluctuations.

OEM/Vehicle Chrysler Group LLC 2012 All Chrysler Vehicles with Automatic Transmissions System Supplier Chrysler Group LLC Material Processor Freudenberg-NOK Sealing Technologies

Material Supplier Chevron-Phillips Resin Ryton R-Y-120 PPS Tooling/Equipment Supplier Freudenberg-NOK Sealing Technologies

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains?css=print

Gas-Assist Injection Molded Coolant Tube

This is the first plastic coolant tube of complex geometry produced for ‘07 MY Ford F250 pickup engine to withstand long life coolant and high engine temperatures.  It was only made possible by gas-assist injection molding of PPS resin.  The resulting part was only half the mass and 20% lower in cost than the conventional metal tubes it replaced.

OEM/Vehicle 2007 MY Ford Motor Company F250 System Supplier International Material Processor Illinois Valley Plastics

Material Supplier Chevron Phillips Resin Ryton® R-4-220 BL PPS Tooling/Equipment Supplier Gain Technology

For More Information See: http://www.plastics-car.com/enginecomponents