Plastic Proliferation of IC engine is the replacement of metal used in car engines by composite plastics.

Concept of plastic proliferation of cars was first invented by Henry Ford.

For years Ford cars had been equipped with plastic horn buttons, shift knobs, door handles and timing gears. Ford was drawn to plastic for its cost- and weight savings as well as its corrosion resistance.

Soybean car :--

After the Ford, Matty Holtzberg was the next person who experimented on plastic car components.

During the 1970s, he made and sold plastic pistons with aluminium crowns to withstand combustion temperatures and plastic connecting rods for racing engines.

In ’79, he founded Polimotor. (the name is shorthand for polymer motor) to develop plastic-intensive engines.

The first Polimotor, a clone of the Ford Pinto 2.3-liter 4-cylinder

Purpose of Proliferation:

a) Light weighting

The EPA says that for every 100 pounds taken out of the vehicle, the fuel economy is increased by 1-2 percent. Based on a gallon of gasoline costing $2.58, this translates to savings of between $0.03-$0.05 a gallon. Of course, 100 lbs. in a small hatchback is going to make a bigger difference than those same 100 lbs. in a Tahoe, so make reasonable assumptions about what going lightweight can offer you.

weight data and fuel efficiency were related as seen in Equation

η = a M-b + c

• For standard vehicles, efficiency equation is,

η = [ (3.01×107 ) / M2.140 ] + 4.54.

• For Hybrid vehicles, efficiency equation is,

η = [(2.21×103) /M0.545 ] – 12.03.

DRIVE CYCLE

EPA

City highway combine

d

Fuel economy benifit

City highway combine

d

MPG MPG MPG % % %

Base line 34.1 46.8 38.9 --- --- ---

Weight--

5% Base line

engine

35 47.6 39.7 2.4 1.6 2.1

10% 35.7 49.2 40.5 4.8 3.0 4.1

20% 35.5 49.6 42.1 9.8 5.9 8.4

reductio

n

5% Engine

downsized

to base line

performance

35.5 48 40.2 3.9 2.4 3.3

10% 35.7 49 41.3 9.4 4.7 6.4

20% 35.4 51.4 44.0 15.6 9.8 13.3

c) Innovative Concepts:

Easy to Manufacture:

Less Friction

Drawbacks plastic materials:

Volatile organic compounds, a class of chemicals that are harmful to breathe

Plastics such as PVC, polypropylene, polyurethane, ABS, HDPE, Torlon etc. And their composites are generally used for this purpose.

VARIOUS PLASTIC MATERIALS

USED FOR PROLIFERATION:

Plastic materials are light in weight as compared to that metal components.

The weight of the component directly affects the

Component Main types of plastics Weight in av.

car (kg)

Bumpers PS, ABS, PC/PBT 10,0

Seating PUR, PP, PVC, ABS, PA 13,0

Dashboard PP, ABS, SMA, PPE, PC 7.0

Fuel systems HDPE, POM, PA, PP, PBT 6,0

Body (incl. panels) PP, PPE, UP 6,0

Under-bonnet components PA, PP, PBT 9,0

Interior trim PP, ABS, PET, POM, PVC 20,0

Electrical components PP, PE, PBT, PA, PVC 7,0

Exterior trim ABS, PA, PBT, POM, ASA, PP 4,0

Lighting PC, PBT, ABS, PMMA, UP 5,0

Upholstery PVC, PUR, PP, PE 8,0

Liquid reservoirs PP, PE, PA 1,0

Total 105,0

1) PLASTIC CONNECTING ROD:

2) PLASTIC MANIFOLD ASSEMBLY:

• Unequal distribution due to metal parts used for manifolds

• Benefits of the use of plastic in construction

MATTY HOLTZBERG:

POLIMOTOR LOLA

• Material used is TORLON

• TORLON can bear temperature unto 500 degree faranhit

• Test of strength: "Mr. Holtzberg campaigned a Lola race car in the International Motor Sports Association's Camel Lights series.

• race lasting up to five hours, the Polimotor engine runs at 8,000 to 9,000 RPM. And the Torlon parts don't melt.

Conclusion:

In this paper, the benefits of the compositeplastics in automotive industry were proposed. Variouscomposite plastics such as Torlon, ABS, these are usedfor manufacturing various automotive parts such as doorknobs, car hood, bumpers. Henry Ford and MattyHoltzberg were experimented and used the compositeTorlon in car engine. The engine so called as Polimotor.Polimotor is a Polymer Motor.

Purpose behind the use Plastic engine is to reduceweight and so increase the efficiency of the car. Alsothere are some drawbacks of these engines. The maindrawback is that these engines emit some gasses whichcause irritation to the driver. Our on-going work focuseson improving the composite plastic properties, whichwill overcome the limitations of the present composites.

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