Whitepaper
Designing air ducts that beat the heat
As automotive and commercial vehicle OEMs continue to drive more performance from internal combustion engine (ICE) powertrains, reducing the weight of...
Optimizing performance and sustainability with advanced air intake systems
By Russell Bloomfield
Application Development Engineer, Envalior
Hybrid vehicles reduce global carbon emissions by combining ICE and battery power for efficiency and performance. To enhance sustainability, manufacturers adopt lightweight materials and compact turbocharged engines. Traditional PA66 struggles under high temperatures and pressures in modern hybrid powertrains, which reach up to 220°C in limited spaces. Envalior’s solutions, including Akulon® Diablo, Stanyl® Diablo, and EcoPaXX®, deliver the durability and performance needed for these demanding applications.
The challenges of modern air intake systems
Hybrid engines, particularly turbocharged designs, operate under higher pressure and temperatures than naturally aspirated engines. Traditional PA66 materials often lack thethermal resistance to perform in these demanding conditions, limiting their suitability for hybrid applications.
Moreover, with limited packaging space in hybrid powertrains, materials optimized for suction blow molding offer the flexibility to incorporate complex duct designs into crowded engine compartments. This ensures that components can be seamlessly integrated without compromising engine performance or reliability.
Advanced material solutions for air intake systems
Envalior’s innovative materials are designed to meet the high demands of hybrid engine air intake systems while ensuring sustainability and cost-effectiveness.
- Akulon® Diablo PA66: Ideal for suction blow-molded parts, it withstands high thermal stress while enabling wall thickness reductions of up to 50%. This reduces both weight and cost for thin, compact components.
- Durethan® XTS3 Stabilized PA66: “Eco-friendly” copper-free and halide-free stabilized material that offers continuous use temperatures up to 200°C.
- Stanyl® Diablo PA46: Provides exceptional thermal and creep resistance with a peak operating temperature 20°C higher than PA66. It offers a 30% improvement in stiffness after heat aging at 200°C and allows for wall thickness reductions up to 10%.
- Xytron® PPS: A lightweight alternative to steel, it excels in exhaust gas recirculation (EGR) applications requiring chemical resistance. It significantly outperforms polyphthalamides (PPA) under prolonged exposure to high-heat acidic environments.
- Arnitel® HT: Optimized for hot charge duct applications, this thermoplastic copolyester (TPC) saves up to 40% in weight and 20% in costs compared to traditional rubber solutions.
- EcoPaXX®: A bio-based, heat-stabilized solution with ultra-low carbon emissions, it is perfect for engine covers and air filter applications, further enhancing vehicle sustainability.
Supporting vehicle sustainability goals
Envalior’s materials go beyond performance to support the automotive industry’s sustainability goals. Arnitel® HT and EcoPaXX® provide recyclable, lightweight, and low-carbon solutions for critical engine components, enabling manufacturers to reduce emissions and improve fuel efficiency. Additionally, Envalior offers comprehensive design consultation services, leveraging over 30 years of expertise to help auto-parts suppliers optimize system performance and meet evolving OEM requirements.
Ready to revolutionize your air intake systems with advanced, sustainable materials? Envalior’s innovative solutions ensure your Hybrid engines meet today’s performance and environmental standards.
Contact us today to discover how our materials can elevate your automotive manufacturing process.
Russell Bloomfield
Application Development Engineer, Envalior
Russell Bloomfield is an Application Development Engineer at Envalior focusing on automotive customers. He has traditionally focused on high-performance thermoplastic materials for automotive air induction and thermal management systems and continues to support these related activities. Russ further supports a host of strategic accounts with application developments including EV battery cooling, advanced driver assistance systems (ADAS), powertrain, suspension and chassis, and actuation. He is one of the regional champions for the Lightweighting Segment Innovation and Advanced Development initiative.
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