Plastic automotive engine

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The Plastic automotive engine has its origins in the late 1970s with research and work done by Matthew (Matti) Holtzberg of Polimotor Research and his associates. [1] Since then Holtzberg and others have done steady work in the field.

Contents

Holtzberg's early work

Matti Holtzberg first attempted to make polymer pistons for an Austin Mini engine in 1969. The pistons ran for only 20 minutes until failure. Holtzberg remedied this by fitting the pistons with aluminium crowns and he sold these pistons to racing builders during the early 1970s. [2]

Mini British car model made by the British Motor Corporation (BMC) and its successors from 1959 until 2000

The Mini is a small economy car produced by the English-based British Motor Corporation (BMC) and its successors from 1959 until 2000. The original is considered an icon of 1960s British popular culture. Its space-saving transverse engine and front-wheel drive layout – allowing 80% of the area of the car's floorpan to be used for passengers and luggage – influenced a generation of car makers. In 1999, the Mini was voted the second-most influential car of the 20th century, behind the Ford Model T, and ahead of the Citroën DS and Volkswagen Beetle. The front-wheel-drive, transverse-engine layout of the Mini was copied for other "supermini" designs including the Honda N360 (1967), Nissan Cherry (1970), and Fiat 127 (1971). The layout was also adapted for larger subcompact designs.

Polimotor research

Matti Holtzberg founded Polimotor Research Inc. in 1979. It was based in Fair Lawn, New Jersey. The company, in cooperation with its suppliers and sponsors, created and raced engines consisting of a large percentage of polymers in the 1980s.

Fair Lawn, New Jersey Borough in New Jersey

Fair Lawn is a borough in Bergen County, New Jersey, United States, and a suburb located 10 miles (16 km) from New York City. As of the 2010 United States Census, the borough's population was 32,457, reflecting an increase of 820 (+2.6%) from the 31,637 counted in the 2000 Census, which had in turn increased by 1,089 (+3.6%) from the 30,548 counted in the 1990 Census.

Version One

Version one was based on Ford's 2.3-liter Pinto engine and weighed 152 pounds (69 kg) (vs. 415 pounds (188 kg) for its cast iron counterpart). It was designed to produce 318 horsepower (237 kW) at 9200 rpm. It was composed of metal cylinder sleeves, metal combustion chamber tops, metal piston crowns, bearings, valves and seats, and a stock 2.3L Pinto crankshaft. Nearly everything else in the engine, including the block, rods and piston skirts, were made of glass reinforced Polyamide-imide thermoplastic resins manufactured at the time by Amoco Chemicals Co. [3] [4] The engine was never installed in a vehicle.

Cast iron iron or a ferrous alloy which has been liquefied then poured into a mould to solidify

Cast iron is a group of iron-carbon alloys with a carbon content greater than 2%. Its usefulness derives from its relatively low melting temperature. The alloy constituents affect its colour when fractured: white cast iron has carbide impurities which allow cracks to pass straight through, grey cast iron has graphite flakes which deflect a passing crack and initiate countless new cracks as the material breaks, and ductile cast iron has spherical graphite "nodules" which stop the crack from further progressing.

Crankshaft

A crankshaft is a shaft driven by a crank mechanism, consisting of a series of cranks and crankpins to which the connecting rods of an engine are attached. It is a mechanical part able to perform a conversion between reciprocating motion and rotational motion. In a reciprocating engine, it translates reciprocating motion of the piston into rotational motion, whereas in a reciprocating compressor, it converts the rotational motion into reciprocating motion. In order to do the conversion between two motions, the crankshaft has "crank throws" or "crankpins", additional bearing surfaces whose axis is offset from that of the crank, to which the "big ends" of the connecting rods from each cylinder attach.

Polyamide-imides are either thermosetting or thermoplastic, amorphous polymers that have exceptional mechanical, thermal and chemical resistant properties. Polyamide-imides are used extensively as wire coatings in making magnet wire. They are prepared from isocyanates and TMA in N-methyl-2-pyrrolidone (NMP). A prominent distributor of polyamide-imides is Solvay Specialty Polymers, which uses the trademark Torlon.

Although sources claimed that Ford had been a partner in creating the engine, [3] [5] Holtzberg was later quoted as saying that "Ford was not involved at all". [4]

Version Two

Another engine, supposedly based upon the Cosworth BDA and YB series engines, weighed 168 pounds (76 kg), half the weight of its metal counterpart. [4] Plastic parts included the engine block, cam cover, air intake trumpets, intake valve stems, piston skirts and wrist pins, connecting rods, oil scraper piston rings, tappets, valve spring retainers and timing gears. [6]

The engine was raced over two seasons. It was raced in a Lola T616 HU04 and competed in the International Motor Sports Association's (IMSA) Camel GT Championship in the Camel Lights (Group C2) category in 1984 and 1985. The car earned several top 5 finishes including its best finish of third in class at the 1985 Lime Rock 2 hours. [6] [7]

Holtzberg patents

Throughout the 1980s, Holtzberg was granted 10 patents for composite engine parts and their methods of production. The patents were issued between 1983 and 1988 and are elaborated on in this section.

The first patent issued was for ignition cables, citing prior art for other non-metallic conductive materials and their ability to reduce RF interference related problems. These cables consisted of a graphite/resin composite conductor strands and a protective silicone sheath. The strands were to be twisted together and drawn through the liquid matrix material, finally being surrounded by the sheath. The two parts would be extruded together to form the cable and ensure a well bound structure of thousands of individual graphite composite filaments. [8]

The majority of patents are for Polyamide-imide engine components, with the potential for graphite, glass or titanium reinforcement as a composite. The inventions are claimed to have a superior stiffness-to-weight ratio, be up to 70% lighter than traditional parts and reduce vibration and forces within the engine. The composite parts are also claimed to reduce production requirements due to being injection moulded with consequently reduced finishing work.

Although the temperature, time and other process variables differ between parts, the general manufacturing process follows. The component is first injection moulded and allowed to cool past its plastic deformation temperature. It is then post cured by solid state polymerisation at a series of temperature steps. This is performed in an inert atmosphere which helps to expel by-products of reactions until the polymer is chemically stable. During this process the heat deflection temperature of the material also increases. The part is now cooled and post-processed. Post processing can take the form of machining, insertion or adhesion of metal parts or a simple cleaning of the part. [9] [10] [11] [12] [13] [14] [15] [16] [17] [18]

Composite Castings LLC

In 1990 Matti Holtzberg founded Composite Castings LLC, based in West Palm Beach, Florida. [2] By 2011 they had developed a V4 carbon reinforced epoxy composite engine block with materials supplied by Toho Tenax. The block is claimed by Holtzberg to be up to 50% lighter than an equivalent aluminium model. The blocks are produced to net shape so minimal finishing work is required to make them ready for use. Holtzberg claims that this reduces tooling and production costs by 50% in comparison to die casting. [19]

Fraunhofer and Sumitomo research

In April 2015 the Fraunhofer group in collaboration with the high performance polymer division of Sumitomo Bakelite Co announced their development of a single cylinder research engine with a casing made of injection moulded glass fibre reinforced phenolic resin (55/45 respective composition). The engine weighs about 20% less than an equivalent of aluminium. Their design uses metal inserts in places of high thermal and mechanical stress, for example in the cylinder liner. [20]

The engine was presented at the 2015 Hannover Messe. [20]

Solvay revival of Polimotor

In May 2015 it was reported that the Belgian chemical company Solvay had shown interest in reviving the concept with assistance from Matti Holtzberg. [4] The engine is planned to weigh less than 148 pounds (67 kg) and generate over 420 horsepower (310 kW), it is also planned to be turbocharged. [4] Several components will be replaced with polymer counterparts, these can be seen in the table below [21] .

PartMaterialDescriptionReference
Cam sprockets PAI 30% carbon fibre [22]
Oil scavenge lines PEEK 30% carbon fibre [23]
Water pump outlet PPA 30% glass fibre [24]
Water pump seal FKM [24]
Water pump internals PPS 40% glass fibre [25]
Fuel railPPS40% glass fibre [26]
Injector o-ringsFKM [21]
Intake runnerPEEK30% carbon fibre, FDM manufactured [27]
Plenum chamber PA6 40% glass beads, SLS manufactured [28] [29]
Oil pump housingPEEK30% carbon fibre [30]
Cam coverPPS [21]

The engine was planned to be installed in a Norma M-20 chassis and raced at Lime Rock in 2016 and a possible Le Mans entry in 2017. [31] [32] However this did not materialise.

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Avgas aviation fuel

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Polyether ether ketone (PEEK) is a colourless organic thermoplastic polymer in the polyaryletherketone (PAEK) family, used in engineering applications. It was originally introduced by Victrex PLC, then Imperial Chemical Industries (ICI) in the early 1980s.

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Polyphenylene sulfide polymer

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Wood-plastic composite Wood-plastic composite

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Polyphthalamide

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References

  1. ↑ "One Step Closer to the No-Iron Car" . Retrieved 2016-06-10.
  2. 1 2 "Is This the Engine of the Future? In-Depth with Matti Holtzberg and His Composite Engine Block" . Retrieved 2016-07-18.
  3. 1 2 3 4 5 "Plastic Race Engine Returns as Polimotor 2 Project Underway" . Retrieved 2016-06-10.
  4. ↑ "Ford in Venture For Plastic Motor" . Retrieved 2016-06-10.
  5. 1 2 "Bob Roemer tells the story of the IMSA T616-Polimotor, the racing car with the plastic engine!" . Retrieved 2016-06-10.
  6. ↑ "1985 Lime Rock 2 Hours" . Retrieved 2016-06-10.
  7. ↑ US 4369423,Matthew W. Holtzberg,"Composite automobile ignition cable",published Jan 18, 1983
  8. ↑ US 4432925,Matthew W. Holtzberg&Lawrence D. Spaulding,"Composite piston ring and process",published Feb 21, 1984, assigned to The Standard Oil Company
  9. ↑ US 4433964,Matthew W. Holtzberg; Lawrence D. Spaulding& Steven J. Henke,"Composite timing gears and process",published Feb 28, 1984, assigned to The Standard Oil Company
  10. ↑ US 4430969,Matthew W. Holtzberg&Lawrence D. Spaulding,"Composite rocker arm and process",published Feb 14, 1984, assigned to The Standard Oil Company
  11. ↑ US 4430906,Matthew W. Holtzberg&Lawrence D. Spaulding,"Composite wrist pin and process",published Feb 14, 1984, assigned to The Standard Oil Company
  12. ↑ US 4453505,Matthew W. Holtzberg&Lawrence D. Spaulding,"Composite push rod and process",published Jun 12, 1984, assigned to The Standard Oil Company
  13. ↑ US 4432311,Matthew W. Holtzberg; Lawrence D. Spaulding& Steven J. Henkeet al.,"Composite valve spring retainer and process",published Feb 21, 1984, assigned to The Standard Oil Company
  14. ↑ US 4433652,Matthew W. Holtzberg&Lawrence D. Spaulding,"Composite valve and process",published Feb 28, 1984, assigned to The Standard Oil Company
  15. ↑ US 4458555,Matthew W. Holtzberg&Billy W. Cole,"Composite connecting rod and process",published Jul 10, 1984, assigned to The Standard Oil Company
  16. ↑ US 4726334,Matthew W. Holtzberg; Lawrence D. Spaulding& Steven J. Henke,"Composite cylinder housing and process",published Feb 23, 1988, assigned to Amoco Corporation
  17. ↑ US 4440069,Matthew W. Holtzberg; Lawrence D. Spaulding& Steven J. Henkeet al.,"Composite piston and process",published Apr 3, 1984, assigned to The Standard Oil Company
  18. ↑ "Carbon fiber engine block revealed  : CompositesWorld". www.compositesworld.com. Retrieved 2016-07-21.
  19. 1 2 "Fraunhofer - Research news 04/2015" (PDF). fraunhofer.de. Fraunhofer. Retrieved 2016-07-21.
  20. 1 2 3 "Polimotor 2 - The Industry's First All-plastic Engine" (PDF). Retrieved 2016-06-10.
  21. ↑ "Torlon® PAI Chosen for Breakthrough Cam Sprocket in Polimotor 2 Automotive Project" . Retrieved 2016-06-10.
  22. ↑ "Solvay's High-Performing KetaSpire® PEEK Polymer Chosen for Oil Scavenger Line in Polimotor 2 Automotive Project" . Retrieved 2016-06-10.
  23. 1 2 "Polimotor 2 All-Polymer Race Engine Project Chooses Solvay's Amodel® PPA and Tecnoflon® FKM for Water Cooling Components and Seals" . Retrieved 2016-06-10.
  24. ↑ "Solvay's Ryton® PPS helps cool Polimotor 2 engine by enabling highly reliable internal components for Pierburg water pump" . Retrieved 2016-10-21.
  25. ↑ "Polimotor 2 All-Polymer Race Engine Project Chooses Solvay's Ryton® PPS and Tecnoflon® FKM for Demanding Fuel Injection System" . Retrieved 2016-06-10.
  26. ↑ "Polimotor 2 Chooses Solvay's High-Performance KetaSpire® PEEK for 3D-Printed Fuel Intake Runner" . Retrieved 2016-06-10.
  27. ↑ "Sinterline® Technyl® Powders Boost Polimotor 2 with 3D Printing Technology" . Retrieved 2016-06-10.
  28. ↑ "Solvay's Sinterline® technology combined with MMI Technyl® Design shape the future of 3D printed functional automotive parts" . Retrieved 2016-11-29.
  29. ↑ "Solvay Announces Polimotor 2 All-Plastic Engine Project Will Mold its Oil Pump Housing from AvaSpire® PAEK Ultra Polymer" . Retrieved 2016-07-06.
  30. ↑ "Solvay materials fuel breakthrough innovation of "Polimotor 2" all-plastic car engine" . Retrieved 2016-06-10.
  31. ↑ "Resurrecting the plastic engine" . Retrieved 2016-06-10.
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