Automotive electronic devices may be exposed to harsh environments, where water, dust, or significant variations in temperature, humidity and pressure, can damage circuits and lead to premature device failure. Therefore, automotive electronics and sensor manufacturers often need to allow venting for pressure and temperature equalization, inside and out of the device, as well as to keep dust, dirt, moisture and other contaminants away from the sensitive electronics. Additionally, many moving automotive parts, components and sub-assemblies, such as axles, transmissions, and brakes, need to vent in order to prevent overheating. Other automotive parts, such as air filters, air bags, and TPMS systems have their own unique requirements for venting, filtering or diffusion.

Polystar Technologies’ sintered porous media provides solutions for these types of challenges. Whichever sintered plastic material is needed for gas sensors, SCR systems, transfer cases, or urea tanks, look to Polystar Technologies to help find solutions to your automotive, on road, and off-road vehicle application needs.

Sensors & Microelectronics

According to MEMS Journal, vehicles produced today tend to carry 60-100 sensors on board. Because cars are rapidly getting smarter, the number of sensors are projected to reach as many as 200 sensors per vehicle in the years to come. These numbers translate to approximately 22 billion sensors used in the automotive industry per year by 2020.  Not all of these sensors can benefit from sintered, porous plastics, but a good number of them will, particularly those requiring:

  • Protection from contaminants
  • Waterproofing
  • Filtration
  • Selective filtration
  • Venting for moving or high-wattage parts

Humidity sensors, gas sensors, certain pressure sensors, and MEMS sensors with frictional and  microelectronics-generated heat, can often benefit from porous solutions that offer protection from dirt, dust, debris, water, and automotive fluids that may affect performance and lead to premature failure.

Mechanical Assemblies

Mechanical assemblies need to operate reliably in harsh and extreme environments. Because they contain moving parts that generate friction and heat, these assemblies need to vent while being protected from contaminants that can increase wear and lead to premature failure. Manufacturers of mechanical assemblies and components look for innovative ways to extend the life of the parts they produce.

The following are just a few mechanical assemblies for vehicles that incorporate porous media:

  • Axles
  • Limited slip couplings (LSCs)
  • PTUs (Power transfer units)
  • Transfer cases
  • Transmissions

Polystar Technologies’ sintered, porous media provides solutions for these types of challenges. Whether the sintered material is polytetrafluoroethylene (PTFE), polyethylene (PE) or other plastic media, if your mechanical assembly needs to operate reliably, vent, and be protected from contaminants, look to Polystar Technologies to work with you to find solutions.

Tanks & Reservoirs

Under-the-hood and under-the-body fluid reservoirs need to keep dust, dirt, moisture and other contaminants out, while allowing venting for pressure and temperature equalization. Changes in temperature cause expansion, contraction, and pressure differentials. Changes in altitude can also create pressure differentials that pull contaminants, whether they are automotive fluids, dirt, dust, debris, fibers or water, into tanks and reservoirs. In every instance, these pressure differentials and the contaminants they introduce can hinder vehicle performance and the performance of related systems. Employing porous, sintered media from Polystar can provide protection from ingress of:

  • Automotive fluids
  • Car wash fluids
  • Dust, dirt and debris
  • Lubricants
  • Water

Automotive tanks and reservoirs often incorporate porous media in ways such as:

  • Brake fluid reservoir vents
  • Fuel tank venting filters
  • Hydraulic fluid reservoir vents
  • Selective Catalytic Reduction (SCR) system vents
  • Urea tank venting filters


Lighting Enclosures

Automotive headlamps, brake lights, and tail lamps need to operate reliably in extreme environments where not only high heat, but also extreme temperature and pressure variations can fog glass or plastic or damage sensitive electronics. Many automotive manufacturers need to keep dust, dirt, moisture and other contaminants out, while allowing venting for pressure and temperature equalization inside and outside of each lighting enclosure. Employing sintered porous media from Polystar Technologies can:

  • Facilitate heat exchange and prevent fogging or condensation in environments where temperatures and pressures can change quickly, causing fogging to occur or condensation to collect;
  • Allow for the venting of sensitive electronics that could be damaged by high heat;
  • Protect electronics from the ingress of dust, water or other contaminants.

Batteries & Fuel Cells

Sintered porous plastics can be used in a variety of battery and fuel cell applications, as separators, vents, and flame arresters. Flame arresters works as a device to cool gas or vapor until it reaches a temperature below its flash point for extinguishing any flame that tries to pass through it. Durable battery vents from Polystar Technologies can be single or multi-component flame arresters that meet all the technical specifications and performance requirements of your design engineering team. In addition to preventing external sparks from entering the battery housing, battery vents from Polystar Technologies can provide controlled flow of air, efficient venting, and optimized back pressure, thereby reducing the risk of off-gassing or acid spillage.