Automakers have one more option when it comes to vehicle lightweighting with the debut of a new blowmoldable grade of heat-resistant polyphenylene sulfide (PPS).
Highlighted at the recent Chinaplas show by Ticona (Kelsterbach, Germany) Fortron PPS 1115LO has already been employed in a charge air pipe by Röchling Automotive (Mannheim, Germany) in combination with a second PPS grade and a new bonding process to reduced the manufacturing cost by as much as 25%. The charge-air pipe is used in VW in 2-liter diesel engines, and is 30% lighter than the aluminum component used previously.
Röchling’s integral application of functional elements on the charge-air pipe assembly was a decisive factor in cost reduction. Previously, brackets, lugs, clips, etc. were injection molded in separate machines and then welded to the blowmolded pipe in a third processing step. With the new JectBonding process, the three operations—blowmolding, injection molding and bonding—are combined into a single fabrication step. The injection molded elements are fabricated with another Fortron grade (PPS FX4330T7). It is reinforced with up to 30% glass fiber, has good flowability, is impact-modified and bonds exceptionally well with the 1115L0 grade.
Fortron 1115LO can be transformed cost-effectively into nearly any shape by means of blowmolding. The polyphenylene sulfide (PPS) is filled with up to 15% glass fibers and features high melt strength and viscosity. That means it can be used to manufacture high-quality products such as pipes with complex geometries. —Stephen Moore