DSM
High-heat automotive air intake manifold in PA / First application in hybrid sports car
 Stanyl Diablo PA 46 delivers performance on the world’s first high-heat plastic air intake manifold with integrated charge air cooler (Photo: DSM Engineering Plastics) |
Dutch chemicals and plastics producer DSM (Sittard; www.dsm.com) has claimed a significant step in the use of thermoplastics in automotive high-heat zones. A recently-introduced hybrid sports car features what is thought to be the world’s first high-heat air intake manifold (AIM) with integrated charge air cooler (CAC) made in PA.
The component is produced in “Stanyl” Diablo OCD2100, DSM’s high temperature resistant PA 46, and operates at 220°C, with peaks up to 250°C, and withstands pulses of high internal pressure. DSM worked with a leading system supplier to develop the AIM/CAC combination, providing development and processing support. The specified material contains 40% glass fibre reinforcement and a specially developed heat stabiliser and provides a significant weight reduction compared with metal alternatives.
The car incorporates a number of technologies that give it the performance of a top-level sports car but carbon footprint lower than that of a compact city car. This is mainly thanks to its hybrid synchronous electric motor combined with a powerful turbocharged 1.5 l petrol engine.
The engine makes use of an extremely high turbo pressure that results in a very high internal air temperature. To cool down the air stream, the engine developer has employed a liquid cooled CAC, which is integrated into the air intake manifold and delivers higher efficiency than an equivalent air-to-air unit.
Integrating the CAC into the AIM reduces the air duct length and improves engine responsiveness. This makes it possible to deliver higher performance while still meeting the latest gas emission requirements, DSM said. However, integrating the cooler into the AIM drives the internal air temperature up to 220°C in continuous use, with peaks up to 250°C, putting additional demands on the manifold material.
Integrated high temperature AIM/CACs have been produced previously, but they have typically incorporated metal components for the manifold. The specified material provides a weight reduction of up to 40% compared with aluminium, and its processing characteristics reduce system cost. The AIM/CAC is assembled from several mouldings using hot gas welding.
The component is produced in “Stanyl” Diablo OCD2100, DSM’s high temperature resistant PA 46, and operates at 220°C, with peaks up to 250°C, and withstands pulses of high internal pressure. DSM worked with a leading system supplier to develop the AIM/CAC combination, providing development and processing support. The specified material contains 40% glass fibre reinforcement and a specially developed heat stabiliser and provides a significant weight reduction compared with metal alternatives.
The car incorporates a number of technologies that give it the performance of a top-level sports car but carbon footprint lower than that of a compact city car. This is mainly thanks to its hybrid synchronous electric motor combined with a powerful turbocharged 1.5 l petrol engine.
The engine makes use of an extremely high turbo pressure that results in a very high internal air temperature. To cool down the air stream, the engine developer has employed a liquid cooled CAC, which is integrated into the air intake manifold and delivers higher efficiency than an equivalent air-to-air unit.
Integrating the CAC into the AIM reduces the air duct length and improves engine responsiveness. This makes it possible to deliver higher performance while still meeting the latest gas emission requirements, DSM said. However, integrating the cooler into the AIM drives the internal air temperature up to 220°C in continuous use, with peaks up to 250°C, putting additional demands on the manifold material.
Integrated high temperature AIM/CACs have been produced previously, but they have typically incorporated metal components for the manifold. The specified material provides a weight reduction of up to 40% compared with aluminium, and its processing characteristics reduce system cost. The AIM/CAC is assembled from several mouldings using hot gas welding.
13.08.2014 Plasteurope.com [229015-0]
Published on 13.08.2014
German version of this article...