DSM
Stanyl Diablo OCD 2305 BM has been developed specifically for hot charge air ducts.
DSM claims it is the first high temperature polyamide suitable for processing by extrusion-blow moulding and with a significant cost benefit compared to PPS, thanks to its lower weight and scrap rate.
The group says it is a more cost-effective alternative to metal and PPS (polyphenylene sulfide) and for thermoplastic hot charge air ducts and capable of resisting continuous temperatures of up to 230°C.
The lower density of Stanyl OCD 2305 BM reduces part weight by 7% compared to PPS. Better wall thickness distribution can potentially reduce weight by over 10%.
The product was developed for the automotive market, where new EU legislation has set stringent emission reduction targets for 2015. This has led to a trend in smaller vehicles with downsized engines. Creating these smaller engines requires new part designs. However, air ducts, either in metal or injection moulded in plastic, do not offer the design flexibility needed to fit complex under-the-hood geometries.
This means that a better solution is to have hot charge air ducts manufactured using blow moulding techniques. The first company to deliver serial ducts from Stanyl Diablo OCD2305 BM is ETM. ETM looked for an alternative blow moulding material to produce hot charge air ducts for Volkswagen.
Speaking on behalf of ETM, Mr. Klockow, General Technology Manager, said: “ETM sets out to meet the needs of its customers both for today and tomorrow. The new DSM material is clearly designed to address the challenges faced by the automotive industry. We are happy to be the company which brings to market the first blow molded ducts made in Stanyl Diablo OCD 2305 BM, approved by Volkswagen.”
With its Stanyl Diablo OCD 2100 and OCD 2300 injection moulding grades of polyamide 4.6, DSM has developed a range of polyamides with high resistance to long term heat aging. The company’s Turbo System Team has built up considerable experience in air management applications over many years. “With this new grade, we are completing the portfolio for air management solutions.” said Kurt Maschke, Global Segment Manager, Turbo System. “We now offer solutions for all temperatures required, with both injection moulding and blow moulding grades.”
According to Kurt Maschke, ducts in Stanyl Diablo OCD 2305 BM are able to withstand temperatures of up to 230°C, according to different OEM requirements: “Because Stanyl Diablo is less dense than PPS, and because processors using Stanyl Diablo have better control over wall thickness distribution compared to PPS, it is possible to make parts in Stanyl Diablo OCD 2305 BM that weigh 10% less than PPS equivalents.
Kurt Maschke suggests that Stanyl Diablo also has very good impact resistance: “It is not unknown for PPS air ducts to crack during handling.” he says. “As a broken part is only checked after assembly, costs can be reduced easily with Stanyl Diablo OCD 2305 BM. It will reduce scrap rate and — even more importantly — reduce the risk of having a broken part fitted to an engine.”