3.5L/3.7L V6 Integrated Coolant Cross-Over

This integrated composite coolant cross-over tube eliminates corrosion associated with aggressive long-life coolants (LLCs) while taking 1 lb of weight and $1 USD cost out of each engine, thereby improving service life, fuel economy, and CO2 emissions while saving money. Previous designs using overmolded brazed metal tubing was replaced by tubing injection molded of 35% GR PPA. Each molded tube is subsequently inserted into a second tool and overmolded with 30% GR PA 6 to form the rest of the intake manifold. Significant structural design work was performed to ensure the hollow PPA tube could survive the pressures of overmolding and special mold-cavity pressure-sensing technology developed by RJG helps prevent damage during the process.  The PPA material was already proven safe with LLC coolants, eliminating corrosion concerns while reducing development costs, and the combined system is now easier to recycle. Further, the intake-manifold supplier now makes its own cross-over tubes, reducing cost variations due to metals-market fluctuations.

OEM/Vehicle Ford Motor Co. 2013 Ford Taurus, Flex, Edge, & Explorer & Lincoln MKZ, MKS, MKX, MKT vehicles System Supplier ITW Tomco Material Processor ITW Tomco

Material Supplier DuPont Performance Polymers Resin Zytel® HTN 51G35HSLR PPA & PA 6  Tooling/Equipment Supplier Luttmann Mold

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