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Air intake systems for the car interior are a potential source of disturbing ambient noise for vehicle occupants but on the other hand offer great potential for acoustic optimization. German Tier 1  Röchling Automotive has developed a new central air distribution manifold for the air conditioning in a middle-class limousine of a large German automobile manufacturer. This technology, among others, is being highlighted at the Frankfurt Motor Show (IAA) by the company (Hall 6.1, Booth B02).

September 22, 2015

3 Min Read
Frankfurt Motor Show welcomes noise reduction strategies from Röchling Automotive

Air intake systems for the car interior are a potential source of disturbing ambient noise for vehicle occupants but on the other hand offer great potential for acoustic optimization. German Tier 1  Röchling Automotive has developed a new central air distribution manifold for the air conditioning in a middle-class limousine of a large German automobile manufacturer. This technology, among others, is being highlighted at the Frankfurt Motor Show (IAA) by the company (Hall 6.1, Booth B02).

The lightweight solution employs a sandwich structure and allows the air noise at maximum air flow to be reduced by 6dB(A) and by up to 10dB(A) in certain frequency ranges. For the upper part of the air conditioning duct, the engineers used the noise-reducing material Seeberlite made of LWRT (Low Weight Reinforced Thermoplastics).

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Stratura underbody protection reduces noise and heat transfer using a light, multilayer construction.

Basically, Seeberlite is a glass fiber reinforced polypropylene (PP) sandwich structure with core and surface layers of different density, but lacking a "tight outer skin." Components made from the material function as acoustic, active-absorbing surfaces on both sides.

This LWRT is also suitable for use with complex component geometries, and the porosity of 80% in the open core layer allows excellent acoustic characteristics thanks to improved sound absorption. In addition, this provides favorable conditions for a significant reduction in weight. Other advantages include the low pressure losses in the air duct system.

Air intake ducts for the engine air also benefit from the Röchling approach. When LWRT is used, an improvement of several decibels is also possible with regard to outlet noise, as unpleasant hiss is filtered out by the absorptive material. This means that there is now a promising lightweight alternative for the high-frequency resonators in the air intake systems which combats the annoying turbo noise. All in all, Röchling precisely matches the engine sound to the requirements of the vehicle manufacturers. From a smooth and balanced sound to a powerful and sporty one, sound design is used to achieve optimum sound quality.

In the new field of complete car body elements made of composites, Röchling has developed a multi-layer car body floor dubbed Stratura, which also adopts LWRT. In production, Röchling uses its Softlofting technology to combine two functions into the LWRT sandwich structures: acoustic and thermal insulation layers, as well as integrated stabilizing aluminum elements. This reportedly delivers optimized NVH behavior. The LWRT material reduces ambient noise significantly, particularly above 500 Hz. Further, the lightweight multilayer car body floor offers protection against stone chipping and corrosion while also providing very good crash characteristics.

As a result of the increasingly stringent global exhaust standards and the associated increase in the demand for selective catalytic reduction (SCR) tank systems, Röchling is also presenting an acoustically optimized, anti-splashing SCR tank for the first time. In selective catalytic reduction, a urea solution is used to transform nitrous oxides in the exhaust gas into nitrogen and water without forming undesired by-products. In the tanks required for this solution, "energy-intensive noise" often occurs at high accelerations.

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