EcoPaXX® Q-HGM24

As OEMs continue to downsize high-performance engines, cooling systems need to be smaller and more efficient. Coolant expansion tanks contain a volume reserve to compensate for volume differences of the liquid and cooling components due to thermal expansion. The coolant expansion tank is also known as the coolant reservoir, or overflow canister.
As the engine heats up, the coolant inside it expands. Without the expansion tank, the coolant would flow out of the overflow tube and be lost from the cooling system onto the street. Instead, the coolant flows into the expansion tank and remains in the system.
The requirements for the materials used in these parts are high.
The material must withstand:
• Under-the-hood temperatures of 105°C to 150°C
• Exposure to water glycol
• Internal coolant temperatures of 120°C to 137°C
• Internal pressure levels of more than 2.3 bar
• Vibration from the chassis or engine

The material must also demonstrate good welding properties, with high strength at the weld line at under-the-hood temperatures. Under these conditions, materials such as polypropylene (PP) and polyamide 66 (PA66) are at the limit of their performance capabilities. Manufacturers using these materials have increased wall thicknesses to meet the higher specifications required for the part. As the specifications for the materials continue to increase with smaller spaces and higher engine temperatures,
manufacturers can no longer improve the part’s performance by increasing wall thicknesses, as the materials have reached their limit due to manufacturing constraints.
 

A drop-in solution when PA66 fails

EcoPaXX® is a bio-based high-performance polyamide 410 (PA410) that provides outstanding performance across a broad range of applications. EcoPaXX® can be used as a drop-in solution without the need for retooling or costly tool modifications in cases where PA66 fails to meet changing requirements. EcoPaXX® demonstrates superior chemical stability and weld-line strength after aging, resulting in a part that lasts up to three times longer, with higher safety margins. This eliminates the need to replace the part during the lifetime of the vehicle, and reduces the risk of hazardous or explosive failure.

Designing for EcoPaXX®

When the coolant expansion tank is designed for production in EcoPaXX®, it can be optimized to fulfill functionality and application requirements at the lowest possible weight and cost. The material’s superior performance, especially for weld-line stability, is so high that the part can be produced with thinner walls, resulting in a 30% reduction in weight and 50% reduction in cooling times versus PA66. This thinner, lighter part design is technically superior, yet cost neutral compared with PA66.

Envalior's polyamide-based UD tapes with endless carbon or glass fiber reinforcements are viable, lightweight alternatives to metals in several applications. UD tapes, tape-based 2D fabrics and crossplies are used in structural and semi-structural applications, as well as in the selective reinforcement of injection molded parts.

A demonstration vehicle door panel made by JLR from carbon fiber-reinforced PA410, as well as fabric sheets woven from the same UD tape (EU-sponsored ENLIGHT project). The UD tape products were thermo-formed and glued to make the panel, which is 60% lighter than state- of-the-art, steel-based designs, while still fulfilling safety requirements. The full composite door consists of structural panels and a tape-wound side impact beam over an extruded, permanent mandrel.

Maxion Wheels and Envalior successfully manufactured and tested (Rim Rolling Fatigue) thin-walled hybrid, steelcomposite automotive wheel-rim reinforced with UD tape (tape-winding) made from glass fiber-reinforced PA410. The hybrid wheel-rim is 2Kg lighter and 30% more fatigue-resistant than state-ofthe- art, steel design, whilst inert to road salts and battery acids.

A vehicle central-floor module from carbon fiber-reinforced PA410 made by FCA (EU-sponsored ENLIGHT project). The UD tapes based ply-books were thermoformed to the final shape. The composite part is 18% lighter than state-of-the-art, steel-based designs, while still fulfilling safety requirements. The composite strength and dimensional stability are not affected by the E-coating process, a requirement of BIW parts.

Details

Benefits

• EcoPaXX® PA410 allows for reliable solutions to its high temperature resistance (better than PA6), its great surface appearanceand low warpage level
• EcoPaXX® PA410 allows for more sustainable solutions due to its excellent carbon footprint (70% biobased) as compared to PA6 and PA66