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Thermoplastic oil pan has increased functionality
APPLICATIONS
Thermoplastic oil pan has increased functionality AUTOMOTIVE PARTS producer ElringKlinger has developed a fibre reinforced thermoplastic pick-up truck oil pan. A key element of the design is the integration of components that are part of the oil-circulation system. This approach not only results in a component that is 40% lighter than its aluminium equivalent but has also led to reductions in manufacturing and assembly costs.
polyamide (PA) 66 thermoplastic resin that is reinforced with 35% glass fibres by weight. This material combination allows ElringKlinger to produce an oil pan that is both very stiff while continuing to offer high impact resistance at temperatures up to 150°C. Other features of the resin system include a high resistance to lubricants, road salts and other media commonly present in and around vehicles.
The new design from ElringKlinger involves the singlestage injection moulding of not just the pan (which measures approximately 550 × 400 mm × 300 mm) but also sections of the pipeline connected to the sump and the fastening flanges for the pressure pipelines to and from the oil filter.
“Our selection of a particularly high melt flow grade of Zytel meant that we were able to manage the long flow distances at a comparably low injection pressure and despite some very low wall thicknesses,” says Ralf Franz, development engineer at ElringKlinger. “This, in turn, reduces cycle times, helps preserve the tool and reduces energy costs.”
The oil pan is manufactured from DuPont Zytel® 70G35 HSLRA4 – a
“The low warp characteristics of the material are a decisive benefit for this application, as it facilitates a durable and reliable seal along the circumference of the oil pan,” he adds. “We had to design the new polymer oil pan in such a way that its connection to the engine was consistent with the metal construction previously used. We were thereby presented with relatively large distances between the connection points. Due to the high stiffness of the material, we managed to limit deformation under load to the required rate thereby ensuring a constant surface pressure across the whole perimeter.” When car oil pans made of thermoplastic polymers were first launched, the initial priority was the replacement of considerably heavier components made of die-cast or sheet metal. Today,
The oil pan is manufactured from a PA 66 resin reinforced with 35% glass fibres by weight.
with the additional design freedom provided by reinforced thermoplastics automotive parts, manufacturers such as ElringKlinger are looking for increased functionality. Dupont; www2.dupont.com ElringKlinger; www.elringklinger.de
Electric aircraft under test YUNEEC International is flight testing its E430 twoseat, composite aircraft, which is said to be the first commercially available electric-powered aircraft. Shanghai-based Yuneec expects the aircraft to be able to fly for 1.5 to 3 hours before its lithium polymer batteries need recharging. The E430 made its maiden flight on 12 June at an airfield near Shanghai and completed a second series of test flights on 20 June. It was on display at the 2009 EAA AirVenture Oshkosh air show in July. Yuneec says that charging times of three hours for as little as US$5 make electric a very low cost way to fly. The company also produces electric paramotors. Yuneec; http://yuneeccouk.site.securepod.com/ index.html
Designed as a LSA (light sport aircraft) aircraft, the E340 is said to be simple to fly, quiet, with no emissions and low maintenance.
www.reinforcedplastics.com
AUGUST/SEPTEMBER 2009
REINFORCEDplastics
Thermoplastic oil pan has increased functionality AUTOMOTIVE PARTS producer ElringKlinger has developed a fibre reinforced thermoplastic pick-up truck oil pan. A key element of the design is the integration of components that are part of the oil-circulation system. This approach not only results in a component that is 40% lighter than its aluminium equivalent but has also led to reductions in manufacturing and assembly costs.
polyamide (PA) 66 thermoplastic resin that is reinforced with 35% glass fibres by weight. This material combination allows ElringKlinger to produce an oil pan that is both very stiff while continuing to offer high impact resistance at temperatures up to 150°C. Other features of the resin system include a high resistance to lubricants, road salts and other media commonly present in and around vehicles.
The new design from ElringKlinger involves the singlestage injection moulding of not just the pan (which measures approximately 550 × 400 mm × 300 mm) but also sections of the pipeline connected to the sump and the fastening flanges for the pressure pipelines to and from the oil filter.
“Our selection of a particularly high melt flow grade of Zytel meant that we were able to manage the long flow distances at a comparably low injection pressure and despite some very low wall thicknesses,” says Ralf Franz, development engineer at ElringKlinger. “This, in turn, reduces cycle times, helps preserve the tool and reduces energy costs.”
The oil pan is manufactured from DuPont Zytel® 70G35 HSLRA4 – a
“The low warp characteristics of the material are a decisive benefit for this application, as it facilitates a durable and reliable seal along the circumference of the oil pan,” he adds. “We had to design the new polymer oil pan in such a way that its connection to the engine was consistent with the metal construction previously used. We were thereby presented with relatively large distances between the connection points. Due to the high stiffness of the material, we managed to limit deformation under load to the required rate thereby ensuring a constant surface pressure across the whole perimeter.” When car oil pans made of thermoplastic polymers were first launched, the initial priority was the replacement of considerably heavier components made of die-cast or sheet metal. Today,
The oil pan is manufactured from a PA 66 resin reinforced with 35% glass fibres by weight.
with the additional design freedom provided by reinforced thermoplastics automotive parts, manufacturers such as ElringKlinger are looking for increased functionality. Dupont; www2.dupont.com ElringKlinger; www.elringklinger.de
Electric aircraft under test YUNEEC International is flight testing its E430 twoseat, composite aircraft, which is said to be the first commercially available electric-powered aircraft. Shanghai-based Yuneec expects the aircraft to be able to fly for 1.5 to 3 hours before its lithium polymer batteries need recharging. The E430 made its maiden flight on 12 June at an airfield near Shanghai and completed a second series of test flights on 20 June. It was on display at the 2009 EAA AirVenture Oshkosh air show in July. Yuneec says that charging times of three hours for as little as US$5 make electric a very low cost way to fly. The company also produces electric paramotors. Yuneec; http://yuneeccouk.site.securepod.com/ index.html
Designed as a LSA (light sport aircraft) aircraft, the E340 is said to be simple to fly, quiet, with no emissions and low maintenance.
www.reinforcedplastics.com
AUGUST/SEPTEMBER 2009
REINFORCEDplastics