Page 55 - Plastics Nuews October 2017

PRoDuCT NEWS

Eaton develops lightweight plastic alternative to traditional A/C

lines

utomotive power management company Eaton Corp. fluid conveyance division, said the weight reduction also
Ahas developed what it says is a cost-effective and offers significant benefits for OEMs working with hybrid
lightweight alternative to the aluminum tubing and and electric vehicles."
rubber components used in traditional air conditioning The value proposition in terms of weight, especially
lines for the automotive industry. The Eaton Polymer Air for electrified cars — either hybrid electrified or fully
Conditioning Conveyance System (PACCS) is made from a electrified vehicles — is significant," Fiedler said. Other
blended thermoplastic material that can withstand high benefits include improved gas tightness, which the
system pressure and offers chemical resistance to oils and company said results in less refrigerant needed. "The
refrigerants commonly used in automotive air conditioning permeation level of plastic is superior to [that of] rubber,"
systems. The thermoplastic material is regrindable and 90
Dehnert said, adding that the new system's lines are made
entirely of plastic, including the flanges for the connecting
joints. Preparation, research and development for the
PACCS lines began in 2012. Since then, Eaton has invested
several million dollars in research, testing, engineering,
equipment, manufacturing and production technology.

"We've set up now probably 70 percent of the manufacturing
needs, which does not yet include the full automation of
the industrialization concept," Dehnert said. Dehnert also
described the use of Eaton's snap-to-connect technology
with the flexible PACCS lines, enabling the elimination
of the conventional process of screwing lines into an air
conditioning system. "We can combine [PACCS] with what
percent recyclable at end of life, we call the snap-to-connect technology, which would
reduce the assembly time in the OEM manufacturing
Eaton is beta testing the prototype with automotive OEMs line significantly, as the screwing [step] can basically be
and expects a full-production launch early next year. The eliminated," he said. Dehnert said Eaton is co-developing
company previously purchased a vehicle and equipped it this application and related new specification with
with the PACCS lines to test the product in real life driving automotive OEMs.In 2016, Eaton Corp. reported sales of
situations and varying weather conditions in Europe. $19.7 billion. Eaton's vehicle group has 46 manufacturing
After undergoing more than 120,000 test miles, company facilities throughout the world.
officials said they found no issues that would deem
the product inadequate. "We had surprisingly positive Eaton's hydraulics business is a worldwide leader in
feedback also about the noise vibration harshness," said supporting companies that want to increase efficiency,
Klaus Dehnert, vice president and general manager of reliability and safety within industries including –
Eaton's fluid conveyance division. The polymer lines construction and mining, agriculture and forestry,
performed better than the comparable traditional traditional and renewable energy, manufacturing and
lines at the get-go of the project," Dehnert added. The processing, oil and gas, transportation and material
lightweight polymer design also enables a 20 to 50 percent handling. The global Hydraulics team designs, manufactures
weight reduction compared with traditional lines and and markets a comprehensive line of reliable, high-
requires 40 percent fewer components, which Dehnert efficient hydraulic and industrial systems including
said leads to lower system permeability, a less complex electro-hydraulics, fan drive, hybrid and steering solutions
manufacturing process and a 10 to 15 percent reduction to leading edge components including adapters, couplings,
in cost. Tom Fiedler, production line director for Eaton's cylinders, fittings and assemblies, hose and tubing,
motors, pumps and valves.

55 Octob er 2017 | Plastics News