Automotive innovation returns: A plastic first for the volvo S40

Once again, aluminum takes a back seat to plastic—this time in a molded underhood component for one of the world’s safest vehicles.

Automakers have been trumpeting the switch to plastic air intake manifolds for roughly 30 years, so it came as no surprise that Mann+Hummel, a leading global producer of automotive manifold systems based in Ludwigsburg, Germany, recently announced a new one. What makes this particular manifold a first is that it appears on a new Volvo vehicle, and represents the first time this particular automaker has adopted a plastic air intake system for any of its vehicles.

The new Volvo S40, a compact sedan introduced at the 60th International Motor Show in Frankfurt in September, represents a departure from the current S40 model mainly in the interior and powertrain categories. Its five-cylinder engine also showcases the air intake module developed by Mann+Hummel together with Volvo engineers. The vehicle will be built in the Volvo Cars factory in Ghent, Belgium. Production is already under way with sales in Sweden only, and the new model will reach the U.S. market early in 2004.

Systems Integration

One of the main drivers to replace the former all-aluminum intake manifold with a molded plastic module was the ability to consolidate several functions. The module contains a dirty air intake with resonators to reduce noise, as well as clean air ducts, all molded of PP. It also features an engine-mounted air cleaner with an integrated antisnow system and an upper intake manifold, both made of 30% glass-filled nylon 6. A throttle module is assembled onto the upper manifold at Volvo’s Swedish engine factory in Skövde.

A lower aluminum intake manifold with connections to remove blowby gases from the crankcase is the only metallic component. Nylon fuel supply rails and injection nozzles are mounted to the lower intake manifold at the Skövde plant. In addition, an electronic engine management unit and air flow meter are assembled onto the air cleaner at this location.Together, the lower aluminum manifold and upper plastic manifold not only integrate functions, but also reduce weight. According to Mann+Hummel spokesperson Marion Degen, compared with the all-aluminum manifold previously used at Volvo, the two-part design reduces weight by 10%. Reduction in the number of components also contributes to lower cost and reduced assembly time.

Degen confirms that Mann+Hummel produces virtually all of the components and has responsibility for the complete module.

R&D Focus

Underlying these types of new products is a targeted research and development effort at all of Mann+Hummel’s locations worldwide. It consists of a three-part approach that employs 450 people and seeks to implement systems and programs in advance of customer requirements.

In the first step, called innovations management, researchers define the direction and strategy of development. Identifying the demands that will be placed on automotive systems in the future is a major goal in this stage. Market analysis and feasibility studies are conducted in parallel with process and technology development. New ideas are assessed by an Innovation Panel, and a yearly prize is awarded to the idea judged to be the best.

During the advanced development phase, products and systems that identify future trends are developed without any specific customer order. According to Degen, the aim of advanced development is to have an answer today to tomorrow’s requirements.

In the development project phase, customers commission Mann+Hummel for specific projects. Thanks to the prior steps, much of the work is precisely defined, including performance requirements, installation conditions, and cost. This helps to reduce product development time significantly.