MANN+HUMMEL Automotive Wins 1997 Society of Plastics Engineers Award for "Most Innovative Use of Plastics"
18 November 1997
MANN+HUMMEL Automotive Is Honored With the 1997 Society of Plastics Engineers Award for "Most Innovative Use of Plastics" in the Powertrain Category
DETROIT, Nov. 18 -- At the Society of Plastics Engineers
awards Ceremony on November 12th, MANN+HUMMEL Automotive was named the
winner in the category of powertrain for their Mercedes-Benz Actros truck air
cleaner.
In close cooperation with Daimler Benz, MANN+HUMMEL developed the air
cleaner for the 1997 Mercedes-Benz Actros heavy-duty truck with the 500 series
engine. Made of DuPont Zytel(R) nylon 66 with 35% glass reinforcement, the
air cleaner incorporates a number of innovative features and replaces the
traditional sheet metal round filter design normally required for heavy-duty
truck applications.
Driven by tight packaging constraints, Daimler Benz was looking to replace
the conventional round metal filter with a flat thermoplastic version. This
presented multiple challenges for MANN+HUMMEL in both the design and
manufacturing stages of the component.
Measuring approximately 1'8" x 2'2" x 1'1", the mere size requirements of
the filter were cause for concern regarding product durability. Under harsh
engine conditions, the filter needed to maintain its flat shape, dimensional
stability, and scaling capability while also withstanding engine temperatures
of up to 300 degrees F. Other essential considerations involved the need for
reductions in Noise Vibration Harshness levels (NVH) and engine pulsation
effects.
Gas-assist injection molding was used in the manufacturing process to
provide the consistent dimensional proper-ties needed at the seal to maintain
the product's extensive sealing profile. Additionally, this technology was
key to obtaining the necessary part stiffness, improved flow to the large mold
and enhanced surface quality required.
Special ribbing and housing contours were incorporated to improve
significantly NVH and enhance the overall stability of the air cleaner.
The added reinforcement additionally served to address the unique packaging
qualifications set by Daimler Benz. The end product is an air cleaner which,
as required, can be mounted horizontally on the engine or vertically behind
the driver's cab.
The results of the effort yielded the world's first flat air filter
housing for heavy-duty trucks, the world's first filter housing to be produced
using gas-assist injection molding and one of the largest automotive
components to be molded in glass-reinforced nylon 66. Additionally, a new
custom sealing material was employed around the filter element to withstand
the extreme temperatures of the engine.
The benefits generated from the effort were not limited to product
functionality alone. Versus an equivalent metal version the Actros air
cleaner achieved both an impressive cost reduction and a dramatic, decrease in
weight of 50%. Enhanced recyclability and an extended filter service interval
contribute to the filters many advantages.
"This product demonstrates not only the tremendous engineering
capabilities of MANN+HUMMEL, but also the extensive manufacturing competencies
that stem from years of experience," said James J. Riordan, president of
MANN+HUMMEL Automotive. "Though we felt that the Mercedes-Benz truck air
cleaner was a great success given the unique design requirements, we are
extremely pleased to also receive the industry recognition."
"As the automotive industry continues to embrace the use of plastics in
automotive applications, companies like MANN+HUMMEL will be challenged to
provide innovative solutions to various under-the-hood components using
composites in place of metals previously used. We look forward to that
challenge as it matches what we believe are our core competencies," said
Riordan.
With 1996 sales of $855 million, the MANN+HUMMEL Group is organized into
two divisions, automotive and industrial. The automotive division which
serves both the OEM and Aftermarket manufacturers components ranging from air,
oil, fuel and cabin filters, to oil modules, air cleaners, composite intake
manifolds, manifold modules and complete induction systems. With 20
manufacturing/sales locations worldwide, MANN+HUMMEL employs approximately
8,000 people.
SOURCE MANN+HUMMEL Automotive