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Du Pont Engineering Polymers : 15 August, 2003  (Company News)
The 2003 Porsche Cayenne
The Porsche Cayenne’s engine delivers up to 450 hp from a lightweight and compact yet powerful, 8 cylinder, V-type engine. The air intake manifold and the two rocker covers were developed jointly by Porsche, system supplier Mahle of Stuttgart and DuPont.

For all the air intake manifold components, Mahle used a special grade of 30 per cent glass reinforced Zytel® nylon resin that is resistant to hydrolysis and hot oil and is also very heat stable. Since Zytel® is easy to weld, the seams have high burst strength, even after ageing.

Mahle carried out the mechanical, acoustic and manufacturing optimisation of the Porsche Cayenne V8 engine rocker covers. DuPont provided technical support with CAD simulations of the mould filling process and calculations of the expected warpage and strength. This helped to avoid sink marks and other surface defects. Use of a 35 per cent glass reinforced grade of Zytel® for the rocker covers ensures maximum rigidity for the overall construction, excellent resistance against oils and other aggressive substances, high heat and dimensional stability and low warpage.

Multi-process technology for air intake manifold pipes
The Cayenne’s air intake manifold is manufactured with close tolerances to ensure a perfect fit. It withstands temperatures up to 150 degrees C, fuels and other corrosive materials. The manifold provides an optimised air supply for maximum power while simultaneously ensuring low noise radiation. It was designed for high strength and rigidity to guarantee the long-term sealing of the system and to meet the tight specification of the twin-turbo engine.

Because it would have been impossible to achieve these characteristics at the same time using a single conventional manufacturing procedure such as the half shell or lost core moulding technologies, Mahle divided the air intake manifold into four components. The resonance pipes, the flanges and the upper and lower plenum parts are all manufactured with comparatively simple and cost-effective tools and connected together.

Rocker covers help to reduce noise
Reinforced ribs on the inner side of the rocker covers guarantee long-term dimensional stability. A high insert gasket groove also increases the rigidity of the construction. Together with a high insert gasket, optimal sealing over a wide temperature range is achieved for these injection-moulded parts. The comprehensive ribbing also reduces vibration. Design innovation using DuPont Zytel® meant that Mahle was able to minimise noise emission from the Porsche Cayenne’s rocker covers.

With 30,000 employees at 65 locations world-wide, Mahle generates revenues in excess of Euro 3 billion and is a leading international automotive and engine supplier. The company develops and builds innovative systems and components for complete engines ranging from small motors through passenger cars to the large power units used in shipping, for example.
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