Accelerating Cleaner Lightweight Motor Efficiency

The fast-evolving Automotive Industry faces many tough challenges in order to meet approaching CO2 emissions standards. Focus on reducing overall vehicle weight while increasing engine efficiency is paramount to satisfy future regulation and competitive needs. Solvay’s Specialty Polymers offer high-performance solutions for improving powertrain efficiency, transmission down-speeding, lightweighting and electrification. Our high-performance materials are ahead of the game for demanding applications where heat and chemical resistance combined with excellent dimensional stability are essential.

Drivetrain Systems

High-Temperature Plastics for Long-Lasting Performance

Solvay Specialty Polymers offer a broad range of high-performance plastics with a proven track record of replacing metal in demanding automotive applications: 

  • Torlon® PAI delivers high strength and excellent wear resistance
  • KetaSpire® PEEK provides very good wear resistance
  • AvaSpire® PAEK offers very good wear resistance and is more cost effective than PEEK
  • Amodel® PPA the most cost effective with good wear resistance

 

Compatible Transmission Designs
  • Dual clutch (DCT)
  • Automated manual (AMT)
  • Continuously variable (CVT)
  • Automatic
  • Front wheel drive
  • Rear wheel drive
  • All wheel drive
  • Light Duty
  • High torque
Key Features
  • Light weight for improved fuel efficiency
  • Parts consolidation for lower manufacturing and assembly costs
  • Noise and vibration dampening
  • Compatible with transmission fluids
  • Abrasion and corrosion resistance
  • High-temperature wear

 

Drivetrain Grades

Torlon® PAI offers a variety of wear resistance grades

  • Torlon 4203L: Unfilled, high elongation, lubricated. Typical applications include check balls, seal rings, and thrust washers.
  • Torlon 4301: High compressive strength, dry and lubricated. Typical applicaions include: seal rings and thrust washers.
  • Torlon 4275: Designed for high speeds, dry and lubricated. Typical applications include thrust bearings, seal rings and thrust washers.
  • Torlon 4630: Excellent wear resistance, dry and lubricated. Typical applications include thrust bearings, seal rings and thrust washers.
  • Torlon 4645: Excellent wear resistance, lubricated.

 

Ketaspire® PEEK: very good wear resistance

 

AvaSpire® PAEK: very good wear resistance. More cost effective than PEEK

 

Amodel® PPA: good wear resistance. Most cost effective

Electrical Systems

Sulfone Polymers Make a Visible Difference

Sulfone polymers are amorphous high-heat polymers that retain their mechanical strength in some of the toughest environments. Unfilled grades offer good ductility and are available in a range of transparent colors.

Udel® polysulfone (PSU) offers exceptional dimensional and hydrolytic stability and has an HDT of 174°C (345°F). Veradel® polyethersulfone (PESU) offers a high HDT of 204°C (399°F) and better chemical resistance than Udel resins.

Key Features

  • High glass transition temperatures up to 220°C
  • Strength and toughness at elevated temperature
  • Excellent hydrolytic stability
  • Good electrical insulation properties
  • High elongation for good ductility
  • Warp resistance

 

 

Udel® PSU

Veradel® PESU

Bobbins

 

Connectors

Fuses

 

Housings

 

Lighting Sockets

 

Relays

 

Sensors

Switches

 

 

Semi-Crystallines Provide Reliable High-Temperature Performance

Amodel® polyphthalamide (PPA) is a family of high-temperature polyamides that retain their high strength and stiffness up to 280°C and maintain mechanical integrity after thousands of hours at elevated temperatures. Their low moisture absorption prevents blistering during IR soldering. These materials are highly resistant to many commonly used electronic cleaning agents, fuels, automotive fluids and road salts. Fast cycle times can lower molding costs.

Amodel® PPA

Amodel resins are available in an wide variety of grades—including high strength, toughened, conductive, high flow, laser welding and flame retardant grades—giving you more ways to optimize performance, processing and price.

Amodel® PPA Key Features

  • High strength and stiffness
  • Continuous-use temperature from 120-185°C at 5,000 hours
  • Withstands SMT processing up to 280°C
  • Low moisture absorption prevents blistering
  • Excellent dimensional stability
  • High flow for thin-wall designs and precision overmolding
  • Excellent electrical insulating properties
  • Good adhesion to silicone and epoxy
  • Meets established OEM specifications
  • Resists automotive fluids, fuels and road salts

 

Xydar® LCP

Xydar® liquid crystal polymer (LCP) is a highly crystalline glass-filled resin that offers exceptional flow properties. It can withstand SMT assembly, including lead-free solder reflow, and retains its high strength and stiffness up to 300°C.

Xydar® LCP Key Features

  • Withstands SMT processing up to 280°C
  • High strength and stiffness up to 300°C
  • Very high flow to fill long, thin walls
  • Mold complex geometries with tight tolerances
  • Outstanding chemical resistance
  • Inherently flame retardant

 

 

 

Amodel® PPA

Xydar® LCP

Bobbins

Connectors

Engine Control

 

Fuses

Housings

 

LEDs

 

Lighting Sockets

Motor Brush Hold

 

Motor End Caps

 

Relays

 

Sensors

Solenoids

 

Switches

 

 

Short term performance at elevated temperatures

Amodel-Xydar-performance-at-elevated-temperatures

 

Long term performance at elevated temperatures 
Tensile strength half life, ISO 2578 thermal aging

Amodel-long-term-performance

 

Water absorption - lower moisture prevents blistering

Amodel-Xydar-water-absorption

 

Mechanical properties and cycle times

One Minute Solder Dip Test

  Amodel®  
PPA
Xydar®  
LCP
PA 4,6 HTN PCT PPS
250°C OK OK OK OK OK OK
260°C OK OK Blisters OK Blisters OK
270°C OK OK Blisters Blisters Blisters OK
280°C OK OK Blisters Blisters Blisters

Blister

Test bars conditioned at 23°C in 50% relative humidity for 48 hours. 
 

Injection molding cycle times

Amodel-Xydar-injection-molding-cycle-times

Fuel Systems

Improve Fuel Economy & Reduce Emissions

The global need to reduce evaporative emissions along with changes in fuel formulations have sparked a strong interest in higher-performing plastics, fluids and elastomers for use in automotive and other fuel-burning engines.

 

Amodel® PPA for High-Temperature Components

For over 15 years, Amodel® PPA has successfully replaced metal in fuel system components where heat is a major consideration. With a heat deflection temperature of 280°C and continuous-use temperatures from 120-180°C, Amodel® PPA delivers the thermal performance you need for the short term as well as the long haul.

Key Features

  • High strength and stiffness
  • Ultra-low permeation
  • Bio-diesel and flex fuel compatibility
  • Long-term fuel contact from 60-125°C
  • Continuous use from 120-180°Cv
  • Resistance to automotive fluids, cleaners and road salts
  • ESD and toughened grades available

 

Average permeability rates over 28 days 
CE10 fuel (90% Fuel C, 10% ethanol) at 60°C

Amodel-average-permeation

 

High Performance Seals

Tecnoflon® fluoroelastomers offer resistance to the most aggressive fuel mixtures while providing excellent properties for the lowest permeation. Tecnoflon® FKM grades have been designed to cover a broad operating temperature range: -40°C to +250°C. Applications include O-rings, fuel line quick-connect seals, fuel sender unit seals, fuel host connectors and fuel cap seals.

Chemical Resistance in Flex Fluids

Fluid Testing in Ethanol Blends, 70 hrs @ 60°C

Tecnoflon-flex-fuel-resistance-in-ethanol

Fluid Testing at Methanol Blends, 168 hrs @ 23°C / 40°C

Tecnoflon-flex-fuel-resistance-in-methanol

Fluid Testing in Biodiesel, 336 hrs @ 150°C

Tecnoflon-flex-fuel-resistance-in-biodiesel

 

Optimal Pipes, Tubes and Hoses

Algoflon® DF 

Algoflon® DF powders are used for pipes and tubings for fuel transport in automotive systems with exceptional performance:

  • Chemical inertness in aggressive environments
  • Thermal resistance
  • Electrical properties
  • Non-stick characteristics in a wide range of temperatures from cryogenic to 260°C

 

Solef® PVDF

Solef® PVDF qualities of impermeability and chemical resistance recommend their use in automotive fuel transport systems. A layer of Solef® PVDF within the construction of a multi-layer fuel line enhances the strength, permeation resistance and durability of the hose.

 

 

Air Induction Systems

Amodel® PPA Outperforms Conventional Nylons

With a heat deflection temperature of 280°C (536°F) and continuous-use temperature up to 210°C (410°F), Amodel® polyphthalamide (PPA) can take the heat in under-the-hood applications that are too demanding for conventional nylons and polyesters. This allows charge air cooler (CAC) housings, airflow valves, throttle bodies and other components molded from Amodel PPA to maintain their high strength and stiffness along with excellent creep and fatigue resistance when exposed to high heat and thermal cycling.

Key Features

  • Excellent mechanical properties over a broad range of operating temperatures and pressures
  • Continuous use up to 210°C (410°F)
  • Excellent resistance to automotive fluids, cleaners and road salts
  • Low moisture absorption
  • Excellent dimensional stability

 

Typical Applications

  • CAC Hot Air Ducts
  • CAC Housings
  • Diesel Airflow Valves
  • EGR Valves & Housings
  • Throttle Bodies
  • Turbocharger Housings

 
 

Wear-Resistant Plastics for Turbocharger Components

Turbocharger bushings, seal rings and other internal components are some of the most demanding applications in air induction systems. They must withstand extreme temperatures, wear, loads and aggressive chemicals in lubricated and non-lubricated environments over a wide range of critical pressures and velocities.

Wear-resistant grades of Torlon® PAI and KetaSpire® PEEK are formulated to give you just the right combination of mechanical and tribological properties to effectively replace metal in high-temperature friction and wear applications.

For comparable PEEK performance with up to 30% lower cost, consider our new wear-resistant AV-700 grades of AvaSpire® PAEK.

 

Key Features

  • Long-term use from 120-265°C (248-509°F)
  • Short-term use up to 280°C (536°F)
  • Lubricated and non-lubricated environments
  • Self-lubricating for longer life
  • Lighter weight and less noise than metals
  • Non-corrosive and non-galling

 

Typical Applications

  • Bearing Retainers
  • Bushings
  • Compressor Wheels
  • Isolation Disks
  • Seal Rings
Lubrication

Fomblin® PFPE High Performance Lubricants

Fomblin® PFPE fluorinated fluids are high performance lubricants with exceptional properties such as:

  • Fuel compatibility
  • Low evaporation weight loss
  • Low noise
  • High viscosity index
  • Anti-wear properties
  • No carbonized residue formation
  • Very long service life at high and low temperatures (-40°C to 150°C)
  • Satisfying Extended Warranties - Components must be designed for lifetime lubrication
  • Exceptional low temperature starting torque
  • Compatibility with plastics, metals and elastomers commonly used in automotive design
  • Elimination of NVH (Noise, Vibration, Harshness)
  • Not affected by most automotive solvents, oils, fluids and gases
  • Oxidation and thermal stability

 

Applications

  • Air Induction Systems
  • Fan & Radiator Lubrication for Cooling & Heating Systems
  • Contact Lubrication for E/E systems
  • Fuel system mechanical and hydraulic components
  • Mechanical components
Wire and Cable

Jacket and Primary Insulation

Sophisticated control and sensing systems have stringent demands for their cabling which only fluoropolymers can deliver. Solvay offers Hyflon® PFA/MFA®, Halar® ECTFE and cross-linkable grades of Solef® PVDF.

 

For applications such as automotive push-pull cables, Hyflon® MFA® offers:

  • High temperature resistance
  • Chemical resistance
  • Smooth surface properties

 

For over-cable jacketing applications and primary conductor insulation, Algoflon® DF PTFE fine powders shows:

  • Outstanding chemical inertness
  • Outstanding thermal resistance
  • Excellent electrical properties
  • Non-stick characteristics in a wide range of temperatures from cryogenic to 260°C
  • Non-flammable materials

 

Specialty Polymers at work