Qualification of Rubber Reinforcement for Application Inside Car Engines in Oil

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2 Qualification of Rubber Reinforcement for Application Inside Car Engines in Oil MPG Seminar: Rubber - a Resilient Future 3 Elastomers in Extreme Environments 16 May 16

3 Outline Introduction Overview of cord reinforcement Advantages of timing belts Developments for Oil resistance Oil plus contamination resistance May 2016 Rubber Reinforcement in Oil 3

4 Nippon Sheet Glass Japanese glass company 625bn 5bn employees Glass for buildings Glass for cars Technical glass Lenses for copiers, scanners Touchscreens for handy Glass flakes Cord May 2016 Rubber Reinforcement in Oil 4

5 Power Transmission Timing Belt Camshaft Driven pulley Belt tensioner Water pump drive pulley Crankshaft drive pulley May 2016 Rubber Reinforcement in Oil 5

6 Timing Belt & Rubber Impregnated Glass Cord 9µ 0.2 mm 1.0 mm Glass cord Fabric 34 tex 9µ sized glass 34.3 tex glass, impregnated with 20% RFL, cured, twisted 34.3/11 tex glass, multiple ends plied together 1.0 mm Overcoat of dried adhesive 15µ for bonding to HNBR 6,600 9µ fibres May 2016 Rubber Reinforcement in Oil 6

7 Glass Cord Function Stiff in tension: 30 GPa Soft in bending: 10 MPa Longitudinal reinforcement of rubber Prevents rubber creep Latex prevents glass abrasion Latex provides adhesion between cord and rubber May 2016 Rubber Reinforcement in Oil 7

8 Timing Belt Advantages Very low creep High modulus Low friction Low NVH Extension ~0.05% Width 20 mm Better timing Lower CO 2 Lower fuel consumption May 2016 Rubber Reinforcement in Oil 8

9 Timing Belt Improvements Durability Life of engine Reduced width 16 mm in field Inside engine Running in oil Oil temperature May 2016 Rubber Reinforcement in Oil 9

10 Car Engines Euro VI (2014) Directive 715/2007/EC 15% of all CO 2 emissions from passenger cars and vans 2020 CO 2 95 g/km NOx 0.04 g/km? Particles g/km? Regulation (EC) 333/2014, 443/2009 per km Gasoline Diesel CO 2, g CO, g THC, g 0.10 NMHC, g NO x, g HC+NO x, g Particles, g Particles, qty 6 x x Lower emissions May 2016 Rubber Reinforcement in Oil 10

11 2020 Emissions How to achieve compliance? Turbo chargers AdBlue Variable valve timing Exhaust gas heat recovery Higher pressures Higher temperatures Hybrid technology (mild hybrids) Regenerative braking Tyre technology Lightweighting Exact, precise timing May 2016 Rubber Reinforcement in Oil 11

12 Oil Resistance Belt in oil Provides low friction Life of engine design Resistant to oil Resistant to oil changes Blow by gas 0.5 to 2.0% Oil initially alkali Combustion oxides SOx, NOx, COx form acids Contamination with alcohols May 2016 Rubber Reinforcement in Oil 12

13 Rubber Tests For oil and water For acid and alkali Elevated temperature Exhaust Gas Recirculation Extended Life Coolant May 2016 Rubber Reinforcement in Oil 13

14 Oil Changes May 2016 Rubber Reinforcement in Oil 14

15 Engine Oil Oil: Initially alkali Combustion oxides SOx, NOx, COx form acids Contamination with alcohols Aqueous: Combustion oxides SOx, NOx, COx form acids Organic acids Alkali with decomposition of glycol Alkali with in situ formation of ammonia May 2016 Rubber Reinforcement in Oil 15

16 Ageing Media FAM A 50% Toluene 30% Octane 15% Di iso butylene (C8) 5% Ethanol Freudenberg: Test A: Fuel 95% FAM A 1% Nitric acid 1% Formic acid 1% Acetic acid 1% Acetaldehyde 1% MEK FAM B (84.5% FAM A) 42% Toluene 25% Octane 13% Di iso butylene (C8) 4% Ethanol 15% Methanol 0.5% Water Test B: Fuel-Oil 75% FAM B 20% Lubrizol OS % Nitric acid 1% Formic acid 1% Acetic acid 1% Acetaldehyde 1% MEK May 2016 Rubber Reinforcement in Oil 16

17 Ageing Media Unimatic: Blow By A: Gasoline FAM B Lubrizol OS Hydrochloric acid Nitric acid Sulphuric acid Acetic acid others? Blow By B: Diesel Lubrizol OS Diesel RME/SME Hydrochloric acid Nitric acid Sulphuric acid Acetic acid others? Rapeseed Methyl Ester Soy Methyl Ester May 2016 Rubber Reinforcement in Oil 17

18 Ageing Media VW Petrol 1 1M nitric acid then dry 2 Lubrizol OS , dry 3 FAM B, dry BMW & Porsche Organic 1% Naphthalene (C10) 44.5% Lubrizol OS % FAM A Asia Organic 49.5% Octane (C8) 49.5% Toluene (C7) 1% PAH Diesel 1 1M acetic acid then dry 2 Lubrizol OS , dry 3 Liquid F, dry Inorganic 10% Formaldehyde (10% in MeOH) 89.7% Deionised water 0.18% Nitric acid 0.06% Formic acid 0.06% Citric acid May 2016 Rubber Reinforcement in Oil 18

19 Media Tests Immersion Typical 72 h 120 C Results change significantly: When to test rubber? Dry? Wash out? Test 2 immersion? Cool in between steps? May 2016 Rubber Reinforcement in Oil 19

20 Extensive Testing in Oil + Contaminants Cord in flat belt Immerse in media Oil Oil + High temperature Measure fatigue resistance May 2016 Rubber Reinforcement in Oil 20

21 Cord Flexibility Hot oil durability test Oil temperature: 130 Speed : 1.7 Hz Tension: 20 N Pulley diameter: 10 mm Cycles May 2016 Rubber Reinforcement in Oil 21

22 Retained Strength Oil Resistance Results 120% Strength after Fatigue Test 100% 80% 60% 40% 90 C 14d 90 C 28d 120 C 14d 120 C 28d 20% 0% Untested Unaged Oil Oil Oil Fatigued Fatigued +Acetic Acid +Glycol Cords unaffected by hot oil + contamination ageing May 2016 Rubber Reinforcement in Oil 22

23 Change in Stiffness (Force 0.8%), % Oil Resistance Results 120 Stiffness after Ageing C 14d 90 C 28d 120 C 14d 120 C 28d 20 0 Untested Heat Oil Oil Oil Aged Aged +Acetic Acid + Glycol Cords unaffected by hot oil + contamination ageing May 2016 Rubber Reinforcement in Oil 23

24 Timing Belts in the Real World Ford EcoBoost Engine of the Year Peugeot PureTech Engine of the Year 2015 May 2016 Rubber Reinforcement in Oil 24

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