Temat: Stanyl®PA46 in TumbleValves Support Efficiency in V6 -and...

Stanyl®, a high-performance polyamide 46 (PA46) resin from DSM Engineering Plastics, was chosen for the production of tumble valve bearings for the latest generation of the V6 and V8 engines of a high value german car producer. Tumble valves are an integral part of the manifold, optimizing the air flow in the combustion chamber. It is the first time that such tumble valves have been produced by assembly molding and Stanyl® played an important role in making this possible.

With the in-mold assembly technique, components are assembled inside the mold in a two shot (2K) process. This results in significant cost savings compared to traditional processes in terms of assembly, tooling, and machinery. For in-mold assembly to work, a combination of materials is required which can meet both the in-mold process demands as well as perform reliably under the operating conditions throughout the life of the engine. In the molding process, Stanyl® has outstanding stiffness at high temperatures - even close to its melting point - which enables 2K overmolding without distortion of the initial molding. As the assembly has a bearing function, free movement of the two components is required after production, requiring that no adhesion occurs between the two materials during the molding process and that shrinkage coefficients are such that free movement is maintained after molding and at engine operating conditions and temperatures up to 150°C.

In addition, wear and friction behavior of the component materials is very important. The tumble valve bearings have to resist high loads which are constantly operating at high frequency when the engine is running. Good wear and friction properties play an important role in the lifetime of the component itself and subsequently the engine. A grade, selected from the Stanyl® portfolio of materials that are optimized for stiffness and improved tribological performance, gave the right performance against the mating material in the assembly (PPS).

"The success of this full plastic tumble valve proves the excellence of plastics in reducing costs while providing functionality", said Thomas Lunow, Technical Engineering Specialist for DSM. "This solution also demonstrates the reliability of Stanyl® in such challenging applications".

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Temat: Stanyl®PA46 in TumbleValves Support Efficiency in V6 -and...

Reduce Significantly Size and Weight of Your Gears with Innovative Material: Stanyl® TW341

Market: Gears - Window Lift, Seat Adjustment, Sunroof Actuation and Sliding Door
Polymer: Polyamide 46 : Stanyl® TW341
Key product performances
• Excellent wear and fatigue resistance: Safety, durability
• Low friction
• Excellent torque resistance (high load at high temperatures)
• High shear modulus at high temperatures
New Gear Design Trends Require Size & Weight Savings
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In areas where space is limited like in window lift application, space savings can help the gear designer tremendously finding extra space in window lift, seat adjustment, sunroof actuation and sliding door applications.

Moreover, gear size and weight reduction trend (miniaturization) provides designers high flexibility in design, weight savings to offer consumers better ergonomy, easier handling, or more compact products. Cost savings associated with miniaturization also allows manufacturers to develop more sophisticated products with limited (or no) increase in price.
Stanyl® TW341 - Material Passing Application Tests in Gears
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In window lift application, the 3000 rpm electric motor was replaced by much smaller 6000 rpm motor creating space savings. The high rpm was compensated by a small extra middle reduction gear made from unreinforced Stanyl®. The measured temperature on the worm gear was 150° C . PA66 was tested but showed melting sign on the surface of the gear and was rejected. Stanyl® was the only material that survived the application tests.
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Temat: Stanyl®PA46 in TumbleValves Support Efficiency in V6 -and...

Replace Metal in Very Demanding Gear Applications with High-Performance Polyamide 46

Market: Gears - Governor Gear Diesel Pump
Polymer: Polyamide 46 : Stanyl® TW241F10
Key product performances
• Excellent wear and fatigue resistance: Safety, durability
• Low friction
• Excellent torque resistance (high load at high temperatures)
• High shear modulus at high temperatures

Diesel Pump: Important Influence on Vehicle Safety & Emissions
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The basic function of governor in a diesel pump is to regulate the quantity of diesel injection for idling and maximum speed of the engine. This is important for safety, driveability, combustion efficiency and emission standards of the diesel powered vehicle. The governor gear is driven by a metal gear mounted on the drive shaft of the pump.

Gears Made from Stanyl® Exhibit Following Performance in Diesel Pump
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Stanyl® exhibits outstanding mechanical performances at high temperatures, excellent chemical resistance as well as excellent wear resistance under severe conditions (temperature and load).

Stanyl® combination of wear & friction performance and high stiffness under high temperature makes it an excellent metal replacement material for demanding high temperature applications, such as gears:

Wear resistance after 2000 hrs testing: Only minimal wear is observed
Temperature resistance test at 100 deg in air for 1000 hrs.
Full load endurance 2000 hrs : Fuel delivery within acceptable limits.
Arizona dust trials 250 h. dust 80 microns 8 mg/ltr of diesel.
Temp shock test +140 and sudden quench to -40 deg C
Temp alteration -40 to 140 deg C
Fuel resistance to diesel + 1.5% water + methanol
Random vibration test at 60G
Sinusoidal vibration 100-2000 Hz 75 hrs.
Mechanical Pulsation 200 N – 1600 N for 10E7 cycles

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