Modules – the shift from metal to plastic

The challenge facing the automobile industry

The goal of vehicle manufacturers is to reduce the weight of their vehicles and in doing so the CO₂ emissions they generate.

The solution

ElringKlinger has made a significant contribution to weight and CO₂ reduction with several newly developed light-weight modules made of thermoplastics. Plastics play a key role within this area, as they are much lighter than metal-based materials and offer tangible benefits when it comes to integrating various additional functions. ElringKlinger has now developed plastic housing modules for more than twenty engine and transmission applications, including cam covers, engine and gearbox oil pans as well as transmission casings.

New design and injection molding technique

Our development activities in this area are centered around a new design and injection molding method for ultra-light plastic cam covers. Applying a new manufacturing method, the division was able to achieve an even lighter material structure, thereby further reducing the weight of a plastic cam cover on top of the weight advantages already gained within this area. Among other things, the company’s development engineers were able to integrate heat shielding, a turbocharger vacuum accumulator and a pioneering oil trap specially designed to cope with the higher peak temperatures and pressure levels in downsized engines.

Combined systems

Other product rollouts include an engine oil pan module for trucks, which is capable of withstanding extremely high mechanical stresses and incorporates various functions such as an oil suction pipe with filter sieve, a release module and sealing components. The company has also focused on developing an intake manifold module made of plastic – another new component that ElringKlinger will soon be producing in series.