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 hybrid 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. Assembly requirements often dictate the use of flexible, rubber components that deliver the high pressure, high temperature air through the air induction circuit.
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. Thus, the challenge lies in the metal and rubber materials that may offer performance, but not design flexibility nor simplicity during the assembly process.
Ideal eco-friendly materials solutions for your air management applications
To overcome performance, flexibility and sustainability challenges, design engineers desire materials solutions that raise the 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
- Reduced system cost as compared to hybrid ducts that incorporate rubber hose
- Single blow/injection molded TPC solution
Our high temperature TPCs (thermoplastic copolyester) set new standards in high temperature flexible air duct applications. For instance, 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.
Also, by using one material there is less potential for leakage because of less parts and connection areas. Plus, a single material solution also makes it easier and faster to process, equating to a system cost advantage and weight reduction up to 50%. Arnitel HT also offers you flexibility and mechanics even at low temperature.
One Arnitel HT application is the 3D suction blow molded hot charge air duct for the Cadillac XT4. In conjunction with the vehicle launch, the Arnitel HT material was recognized as runner-up for innovation in the Enabling Technology category during the 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 Envalior, 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.
Another blow moldable solution that can handle continuous use temperatures up to 220°C is the Akulon Diablo HDT2504 BM and HDT2505 BM materials. These material solutions offer you weight reduction up to 10% vs PPS and up to 30% vs aluminum, along with improved long-term temperature capability and superior strength-at-temperature as compared to traditionally available PA66-based blow moldable materials.
Both Arnitel and Akulon Diablo materials 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.
