High-heat resin simplifies fuel filter

In order to increase flexibility and reduce cost, Engineers at Purolator selected a grade of Radel R polyphenylsulfone (PPSU) for the housing of a transaxle fuel filter. The transaxle/filter is part of an electric power train being developed and tested for use in future fuel-cell vehicles. The entire assembly consists of a stainless-steel mesh filter element and three injection-molded components made of Radel R-5100. The injection-molded parts include a base and end cap for the mesh element, plus a housing that encloses the filter.

Radel R PPSU was selected for its high heat deflection temperature and chemical resistance that surpasses that of other amorphous polymers. Two other major factors in the material selection were cost reduction and simplification of the manufacturing process.

“Molding the components in Radel R resin allowed us to consolidate parts and eliminate an adhesive,” says Brian Yates, director of product engineering for Purolator. Induction-coil heating is used to raise the temperature of the PPSU parts until they are almost molten, at which point the stainless-steel mesh is embedded in the plastic end and base caps.

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