Turbocharged Air Duct

This application combines the air-intake duct with charge air cooler and integrates both into the intake manifold, reducing air-intake loop volume by up to 50% (for better engine response) while also lowering package space 40% and part count, weight, and costs by 20%.  The resulting system reduces pressure losses so turbine work is reduced while keeping the same boost pressure at air-intake valves and helping reduce pumping work in the turbocharger 10% at high engine loads. Novel production technology (suction blow molding) and a new high-performance soft TPV (PA6 & ACM), which can withstand 2.7 bars of overpressure at 125C were used. There was no need for bellows, since the material was able to decouple engine movements from the intercooler by itself, and no internal protection layer was needed to protect the material from exposure to acidic blow-by fluids. Unlike conventional rubber, the part is fully recyclable at end of life. This led to a 50% direct and 50% indirect cost savings. Thanks to acoustic improvements, interior cabin noise also is reduced for occupants.

OEM/Vehicle Audi AG 2011 Audi A4 & A5 2.0L TDI & TFSI System Supplier Röchling Automotive Material Processor Röchling Automotive

Material Supplier ZEON Corp. Resin PA 6 + ACM Tooling/Equipment Supplier Röchling Automotive

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior/Air-Ducts.html