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05/10/2003
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The world’s first oil module with an all-plastic housing has gone into series production.
 Developed by German company Mann & Hummel in conjunction with Bayer Polymers, the module is manufactured from Durethan, a 35% glass fibre-reinforced polyamide 66 that is specially designed to withstand high temperatures and is also used on the Audi A3 2-litre FSI engine.
The innovation is a great example of metal replacement in engine design and recently received an Automotive Division Award from the Society of Plastics Engineers (SPE), Central Europe, taking first place in the Power Train category.
The oil module has advantages over comparable die cast aluminium designs. Its production is more cost effective for example. Whereas the drill holes, threads, openings and flanges on metal oil modules need some degree of mechanical working, injection moulding produces a finished component. And there is less scrap due to fewer production process stages while additional functions such as oil cooling, crankcase ventilation, sensors and control or bypass valves are all easily integrated into the design. The module is also 300g lighter than the aluminium equivalent and is suitable for recycling.
As a material, Durethan displays a very low tendency to warp, ensuring moulded parts remain
highly planar with correspondingly tight flanges. The material can be worked in such a way as to create a glass fibre surface so that no glass fibres can find their way into the oil circuit. Durethan is highly resistant to pressure and stress fluctuations.
Work is currently underway to launch series production of similar oil modules with new concepts for additional car engines in the pipeline. DP
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Author
Tom Shelley
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