Solvay’s Ryton PPS used in automotive thermal management systems

Solvay has launched its first batch of Ryton polyphenylene sulphide (PPS) extrusion grades that complement its PPS injection molding materials for use together in automotive cooling line assembly applications. The new Ryton PPS extrusion series is globally available in three grades: Ryton XE3500BL, Ryton XE4500BL and Ryton XE5500BL.

Since 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. Photograph: Solvay

The stiffness of these grades varies between 1500 MPa and 2500 MPa to fulfil requirements of flexible tubes with different wall thicknesses and diameters or for post-extrusion thermoforming. Flexible coolant lines made using Solvay’s new extrusion polymer technology reportedly exhibit high melt strength, chemical resistance and thermal stability with enhanced tensile elongation and impact strength.

Solvay’s injection molding grades include Ryton XE5430BL (30 percent glass filled) and Ryton R-4-270BL (40 percent glass filled). These materials have exhibited a proven fit in many existing connector and bracketry fittings to enable automotive OEMs to design fully harmonized and integrated coolant line assemblies for engines and transmissions. 

“Under-the-hood temperatures are pushing existing cooling line design and material solutions to their limits, narrowing the safety margin,” says Andreas Lutz, European Area Development Manager for Solvay’s Specialty Polymers global business unit. “Engine downsizing along with the generalization of high-temperature components such as turbochargers, superchargers, automatic transmissions, 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.” Continuous use temperature of Ryton PPS extrusion grades are 170°C in air with short term performance to 190°C.

Since 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.

Solvay’s Ryton PPS extrusion technology can help OEMs replace cumbersome and expensive powertrain fluid handling lines with sleek, light, integrated solutions that include connectors, over-molded brackets, and welded brackets made from Ryton PPS injection molding grades.

While some major European automotive OEMs have already integrated lightweight Ryton PPS solutions, others are investigating their use across a variety of coolants as well as engine and powertrain oil handling systems, seeking to replace incumbent mixed material (metal/rubber) and polyamide (PA) designs. “The more complex a fluid handling line is, the more instrumental Ryton PPS can be in reducing weight as well as simplifying manufacturing and assembly costs,” adds Lutz.

 

 

 

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