Intake Manifold with Fully Integrated Intercooler
The new system exploits all the advantages of indirect charge air cooling and requires a lower number of components in comparison to standalone concepts that work with separate components for the intercooler and intake manifold, Mann+Hummel explains. This reduces the number of interfaces and the handling costs for car makers. In addition, a lower pressure drop and smaller charge air volume should improve engine response.
Full integration versus mounted units
With full integration, the cooler is completely enclosed by the intake manifold shells. This gives the whole system a higher stability in comparison to mounted solutions since there is no sealing surface to the outside according to the supplier. The system enables excellent temperature distribution with a maximum temperature difference of two kelvins over all six cylinders. The whole system has to withstand high temperature differences between the air inlets and air outlets of up to 90 kelvins in the process.
The seal, which consists of two components between the cooler and intake manifold shells, exhibits good resistance to chemicals and low leakage values according to the company. It is made from a plastic frame in polyamide 6 with a 35 percent glass-fibre component (PA6 GF35) and an elastomer seal in fluorinated rubber (FKM), which should have good resistance to temperature and media. A positive-locking fit binds the polyamide with the elastomer.
Stable and light
Mann+Hummel is aiming to ensure the highest stability and at the same time optimise weight by using ribbed plastic shells. Guiding ribs in the assembly are designed to ensure an even air inflow to all the cylinders, thereby producing an optimum air flow. At the same time, the component design ensures a minimal pressure drop. Use of hot-gas welding enables narrower yet stronger welding seams. A positive side effect is that components are cleaner since no fluff is generated by friction with this process.