POLYTEC PASSION CREATES INNOVATION

POWERTRAIN SOLUTIONS

POLYTEC PRODUCTS MEAN CLEANLINESS AND EFFICIENCY IN THE ENGINE COMPARTMENT


​​​​​​​The Powertrain Solutions product series incorporates comprehensive competences for car and commercial vehicle engine compartments. Irrespective of whether cylinder head covers, oil separators, oil pans, air intakes, crankcase ventilation, covers, or fuel cell applications are involved, POLYTEC offers solutions that set new standards with regard to both the use of materials and engineering.

PKW Ölwanne

FUNCTIONAL INTEGRATION

WE REDUCE THE NUMBER OF PRODUCTION STEPS AND THUS SAVE COSTS

POLYTEC has established an excellent reputation through its innovative solutions for functional integration and the fact that considerable potential still lays dormant in the engine compartment is demonstrated by the oil pan of the Porsche 911 Carrera. In this case, by combining the functions of the air-oil separator, the switch box and the oil lines, POLYTEC not only reduced the complexity of the component, but also its weight.

 


Highlights:

  • A weight reduction of 36% as compared to the aluminium predecessor model

  • Cost reductions as a result of design freedom, functional integration, process reliability and reworking elimination

SYSTEM INTEGRATION

THE LINKAGE OF VARIOUS FUNCTIONAL ELEMENTS TO FORM A COMPONENT SYSTEM

Maximum precision and integrated design are of special importance in the engine compartment, in order to ensure that every available inch of space is used to optimum effect. For example, POLYTEC employs the advantages offered by hot gas welding to both integrate all the functional elements involved in crankcase ventilation and join highly complex geometries. System integration thus combines 55 individual parts, which include non-return valves, lines, gaskets and separation systems, to form a single, ready-to-install product.

 


​​​​​​​Highlights:​​​​​​​

  • Implementation of highly complex, three-dimensional welds

  • Prevention of the formation of loose particles or dust

  • Economic integration of all functional elements in a single, ready-to-install product

Oil Separation

OIL SEPARATION

HIGHER CLEANING LEVEL AND LOWER COSTS

POLYTEC also sets benchmarks with regard to the cleaning of crankcase ventilation gases. In combination with a multi-level, suction jet pump, the group’s in-house developed, differential pressure controlled oil separator facilitates higher blow-by gas purity in both the idling and full load modes. As a result, our customers profit from simplified and more efficient combustion gas cleaning, the protection of the turbocharger against soot and reduced engine oil consumption, which permits longer intervals between servicing.

 


​​​​​​​Highlights:

SEPARATOR:

  • Freely scalable and higher oil separation performance at lower cost as compared to disk separators

  • Clean combustion gases owing to extremely efficient oil mist separation

  • Universal plug & play separator (Otto and diesel engines)


​​​​​​​PUMP:

  • Customisation possible

  • Electrical elements and drives are unnecessary

  • Universal applications: tank and crankcase ventilation, fuel cells ​​​​​​​

BATTERY APPLICATIONS

MODULAR HIGH-VOLTAGE BATTERY HOUSINGS

POLYTEC's modular high-voltage battery housing offers stable protection and meets a wide range of requirements thanks to the combination of different materials. Whether cell carrier, housing cover or tray: each module fulfils specific tasks - from encapsulation and shielding of electromagnetic radiation, cooling and ventilation to impact and fire protection. During development, attention was also paid to improved recyclability through the dismantlability of the individual modules.

GROWING MARKET,

GROWING PORTFOLIO

POLYTEC does not just develop ultralight components for electrically powered cars, which help expand the range of these vehicles. The infinite mouldability of plastic and its combinability with other materials also enable solutions that combine stability, fire protection, heat insulation, crash safety and shielding from electromagnetic radiation in one module. With the establishment of the new Battery Applications Product Line, the traction battery portfolio of the POLYTEC GROUP is growing more diversified year by year.

 


​​​​​​​Highlights:

- Modular solution for prismatic as well as cylindrical battery cells

- Optimised multifunctionality ensures stable protection and increased passenger safety

- In-house product development with consistent environmental and climate protection

HIGH-VOLTAGE BATTERY HOUSINGS

COMPLEX NEW DEVELOPMENT

In a designated engineering stream POLYTEC works on the development of highly stable and fire-proof housings for high-voltage batteries. Such housings are currently primarily manufactured from steel and aluminium; in the future lighter weight solutions should be produced. In 2022, POLYTEC presented a completely new solution made of plastic, which is not only significantly lighter, but also impresses with its functional integration, repairability and recyclability.

The new POLYTEC high-voltage battery housing is made up of five individual modules. Each of them consists of different parts and materials and fulfils special functions such as electromagnetic shielding, cooling and ventilation, or fire and impact protection.

From material selection to the extensive and highly complex test series, the entire development of the battery carrier took place exclusively at POLYTEC. The housing primarily consists of SMC and glass mat reinforced thermoplastics (GMT).

SUSTAINABLE PRODUCT DEVELOPMENT

In the development of the modules, the engineers also kept an eye on environmental compatibility every step of the way. All components of the housing can be easily separated at the end of their life cycle, which makes them easier to recycle.

Looking for a more efficient solution for the engine compartment?

CONTACT THE POLYTEC SOLUTION FORCE