Less Fuel. More Drive.

Rchling Automotive Prole

Get There Quickly with Rchling

Benets for Customers Across the Globe

The Rchling Group, established in 1822, has operated in the eld of plastics processing for over 90 years. Our globally positioned group of small and medium-sized companies is characterized by its innovative applications for a broad spectrum of industries. Our customers value the quality of our products, a result of a close partnership, a high level of innovation, and expertise in product and process solutions. They benet from global standards as well as the power of a strong group. Rchling Automotive aims to provide vehicle manufacturers and their customers with future-oriented technology in the elds of air ow management and acoustics, lightweight construction, and thermal management. Over 3,500 employees working at development centers and production sites in every world market help reduce CO2 emissions and noise pollution, lower air resistance and friction, and keep the total costs of producing a vehicle as low as possible. Our uncompromising slogan is: Less Fuel. More Drive.

Competence. Quality. Innovation.

Competence: Air Flow Management

On Point: Quickly and Efciently -- Optimized engine performance with the help of aerodynamic ow simulations (CFx) in single and multichannel systems -- Reduced weight by integrating the charge-air cooler in the intake manifold, simplifying component designs and substituting metals -- Reduced resistance through intelligent air ow guidance at the front and underbody of the vehicle -- Enhanced driving enjoyment with the design of complete air intake systems built for durability, performance, and the perfect sound -- Increased customer benet by taking a holistic approach to development and validation

Directing the Flow

Competence: Acoustics

Pitch Perfect -- Integrated acoustic features in lightweight materials -- Noise damping and absorbing components for underbodies, engine compartments and passenger compartments -- Engine simulations with GT Power for that extra performance boost and customer-specic intake acoustics -- Sound designs with or without low and high-frequency resonators -- Acoustic and aeroacoustic calculations for both far and near-eld with FFT Actran and other software solutions -- Stationary and mobile measurement devices for verifying acoustic improvements -- Specialists with knowledge on the correlations between material composition, acoustic properties, and their effects

Bringing Silence to Life

System: Engine Air Intake

07 Simulate Reality Accurately
There are many ways to achieve goals. With complete intake systems, technology and costs are the major hurdles to overcome. Simulation expertise, innovative spirit, and engineering commitment are the keys to developing a system successfully and time-saving. Another important factor is the experienced team of specialists who develop and produce the systems individual components. Strong in the details, yet remaining exible: Thats how Rchling Automotive has made a name for itself as a system supplier.

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Intake section, developed and produced by Rchling Automotive

Tracking down pressure losses

Determining air ow speeds

Downsizing by Integration
A new topology of the intake section, with the chargeair cooler integrated in the intake manifold, saves 40 percent on air volume and installation space as well as 20 percent on components, weight, and costs.

Campbell diagram before and after acoustic optimization

Air lter housing made from 99 percent Plantura biopolymers

Less Weight, More Performance

Reliability Starts with the Filter

09 The Art of Coordination
Intake systems are characterized by excellent ltration, long maintenance intervals, and a minimal loss of pressure. Numerous requirements for hot or cold regions need to be observed. Acoustics are playing an increasingly important role. From simple air lters to multi-level ltration designs: The air ow management and acoustic expertise of the developer represents a benet to the customer. As do the various manufacturing techniques. The end result is satised drivers pleased with their vehicles low maintenance costs, driving enjoyment, and great sound. The environment also benets from the quieter outlet noise.

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Functionally optimized air lter housing

Radiation cross-linked clean air tube with Helmholtz resonator

High performance solutions for sports cars

Air Filtration
-- Great range of vertical manufacturing and exibility from producing our own paper lters -- Fleece lters for greater durability and improved ltration results -- Various pre-ltration designs -- Maximized lter dust capacities through optimal particle distribution -- Forecasted lter service life -- Quick presentation and evaluation of options due to high-performance system development

Sound Design
-- Targeted optimization according to customer wishes -- Integration of noise dampers in the air intake system -- Helmholtz and quarter wave resonator tubes as well as high-frequency resonators -- Use of acoustic cones -- High precision 1D and 3D acoustic simulations -- Great freedom in construction thanks to modern manufacturing technology and clever material selection
Air lter Twins for the premium class

Air lter cartridges manufactured in-house

Optimizing acoustics

Air ow analysis

From Turbo to Combustion Chamber

11 Pressure in the System
Air tubes and intake manifolds are designed almost completely digitally. This greatly aids in ensuring that high temperatures combined with major uctuations in pressure do not lead to mechanical failure even after extensive periods of operation. To accomplish this, air ows, acoustics, and material selection need to be optimized. Time invested in design and technical engineering features often result in elegantly simple and innovative solutions. The spectrum of applications stretches from small suction and turbo engines to large-volume highperformance engines, from compact cars to luxury sport sedans.

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Pre-intercooler duct, up to 230C

Flexible, wrinkle-free 3D lightweight charge-air tube

Two-channel intake manifold

Charge-air Tubes
-- Flexible piping using one-component and twocomponent blow molding technology -- Resistant to aggressive substances -- Plastic return pipes for temperatures up to 230C -- Mounting elements attached with high cohesiveness thanks to Jectbonding -- Intelligent injection molding solutions -- Unique test stands and validation facilities

Intake Manifolds
-- Built-in shifting mechanisms and aps -- Charge-air cooler integrated in the intake manifold -- Multi-channel solutions -- Optimized and harmonized air ows thanks to highperformance software -- Constructed according to acoustic requirements -- Comprehensive testing technology -- Joining shell over injection

SPE-Award

Precision is our focus

Joining by overinjection

Intake manifold, made in Polypropylen

Thermoacoustic Engine Encapsulation

13 Sound and Energy
With clever engineering, engine noise emissions can be brought to lower levels without having to sacrice much installation space. The keyword here is acoustic integration in lightweight construction materials. Here, Rchling Automotive offers a unique spectrum of various material and production approaches. Databases holding characteristic values collected from our acoustics laboratory help in design planning. Thermal imaging data provides insights into the thermal loads of various components. Thermal conductivity values are crucial for heat dissipation and thermal isolation. Every design is custom tailored to meet customers specic needs.

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Engine-side second front wall, sound insulating

Second rewall, sound absorbing

Heat stays in the engine compartment with encapsulation

Partition walls
- Air and water-tight separation of the engine compartment from the air intake - Sound insulated feed-through of steering column, cabling, and supply wires - Constructed to meet pedestrian impact requirements - Various materials available with lled plastics - Solutions with or without foam absorbers - Broad spectrum of manufacturing approaches

Engine Isolation on the Sides

- Various approaches for sound absorption - Thermally insulating materials - Temperature-resistant lightweight constructionComposite materials - Full-body and partially placed aluminum heat shields for lightweight reinforcement materials - Blow molded solutions - Integrated seals and brackets

CO 2 management: Thermoacoustic insulation

Drive-by sound level measurement

Engine compartment Partition wall made with SMC

Thermal imaging data

Smart Cooling Air Controls

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Air Radiator grill Cold start Interior/glass Noise level Flap open Flap shut

Less CO2
Controllable air ap systems lower fuel consumption and CO2 emissions. One reason for this is reduced air resistance with the aps closed. These aps close or remain closed when greater cooling capacities are not needed or desired. The movement of the air aps is usually controlled with a sophisticated actuator system. Benet for the customer: many aerodynamic advantages as well as engines that warm up faster and stay warm longer. Rchling Automotive develops and validates component designs for customers throughout the entire world: For both passenger and commercial vehicles independent of the drive system.

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high cooling capacity improved aerodynamics unprotected normal warms up normally normal protected accelerated accelerated warm-up lower

Competence: Actuators
- Complete solutions - Customer-specic validation, wind tunnel testing, LIN conformity tests and error diagnostics within the vehicle using vector software - Integrated FailSafe functionality

Open / closed according to customer wishes

Active air ap system

Controlled Shutter Systems

- Improved drag coefcient - Fuel savings of approximately 1% in average European driving cycle - Lowers emissions - Shortens cold starts - 1dB noise reduction for diesel engine cold starts - Accelerated warm-up times for passenger compartment - Shortened windshield defrost times - Electric auxiliary heater can be downsized - Protects the cooler pack - Can be used with any drive system - Especially effective for frequent drivers

Modules with multiple rows of aps, centrally controlled

Modular solutions for various vehicle models, with and without ornamental grill

Actuator development

Deectors for further optimization of aerodynamics

Deector frames with up to 99 percent organic material

Aeroacoustics for the Interior

17 More Comfort
Passengers of vehicles with Rchling Automotive products should travel with peace of mind. Considering the effective separation of air and water, optimized channel air ow, and noise-reducing measures, innovation is redening the state of the art. Detailed ow analysis, advanced manufacturing technology, and acoustically effective lightweight construction materials represent the foundation for product ideas that make driving more enjoyable. Special measuring techniques and testing methods round out the service offer.

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Windshield cowl with integrated pedestrian impact protection Hollow prole soft seals produced using projectile injection technology

Air intake with lter

Acoustic climate channels made of lightweight materials

Air/Water Separation
- Multi-functional windshield cowls and water collectors - Secure drain pipe - Various sealing designs - Optimized separation of air and water - Integrated mounting devices - Experience with various designs - Single and multi-piece variations

Climate Control
- Flow analyses for individual components and complete systems - Optimized ows - Minimal loss of pressure - Absorbing materials - Thermally insulating materials - Integrated switch aps

SPE-Award

Seals are mechanically and acoustically optimized

Acoustically effective housings for A/C units

Complete air distribution system

Competence: Lightweight Construction

Save Weight without Sacricing Safety - Acoustic lightweight construction using multi-layered material compositions - Perfect balance of strength and stiffness using targeted ber alignments and optimized ber/matrix adhesion - Broad spectrum of modern innovative processing technology - Sophisticated joining and mounting techniques - Material and process technology in close coordination - Lightweight construction - Integrated solutions

Developing Top-class Models

System: Underbodies
21 Light, Acoustically Active Absorption Surfaces
Vehicle manufacturers know the consumption reducing effects a shielded underbody can offer. They are also aware of the safe and powerful driving dynamics it provides along with high acoustic comfort for both passengers and environment. Rchling Automotive supports this efforts through extremely light composite materials with various porous cores and coatings.
dB 60

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With a minimum of installation space, underbody shields manufactured with the Softlofting process achieve excellent acoustical values at the lowest possible weight per unit area. The process also allows mechanical values to be set to the highest requirements.

overall level [dBA]

69.1 68.5 68.1

without underbody

50
Hard plastic underbody + additional absorber on the upper side

40

Seeberlite 2

30

31,5

100

315

1k

3,15k

10k

Hz

Interior road noise in the back of a luxury-class sedan measured at 100 km/h

Lightweight underbody with textile and injection molded wheel arch liners

Modularly constructed underbody

High-temperature Solutions
Perforated aluminum foils, which are applied to generally multi-layered underbody materials during the manufacturing process, reliably dissipate the heat radiated from the exhaust system. Alternatively, Rchling Automotive offers its customers high-temperature resistant underbody materials a novelty that enhances integration in the vehicle oor.
Aero-acoustic underbody with molded cooling channels and large-surface perforated aluminum foils applied

Lightweight Design, Solid Performance

Working Together to Reduce Emissions

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weight per area

glass content

tensile stregth

Functionality in Tight Spaces

The product solutions developed for our customers around the world need to conform to various specications. Close cooperation with our customers during development and internal testing facilities, such as the water track, allow for streamlined development times. The decisive element next to feature integration is the choice of the right material. Acoustic and strength parameters can be adjusted as can the water absorption, ammability properties, and temperature stability.

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thickness (acoustically)

tensile E-module

thickness (compact grouted) Seeberlite DLFT

Side body undershields with area densities of less than 1,000 g/m

Chipping resistant engine undershield comes in various models

Textile wheel arch liner

Engine and Body Undershields

- Substantial reduction of interior and exterior noise levels - Best in class lightweight construction with Softlofting - Proven mechanical integrity - Especially chipping resistant solutions - Large surfaces with few mounting points - Covers for the exhaust system with and without aluminum sheets - Thermally insulating effect

Wheel Arch Liners and Ram Air Lips

- Single and multi-part injection molded solutions in one-component and two-component constructions - Stable textile solutions for lower weight and improved noise damping - Various designs for aerodynamic improvements using ram air lips - Built-in cooling slits - Various sound absorbing materials

Exhaust system cover with cool air openings molded into the material

Insulator in D-LFT with built-in maintenance ap

Preparations for vehicle testing

2-component solutions

Competence: Thermal Management

Because All Energy Is Useful - Concepts and components for quick heat transfers in tight spaces - Thermally insulating materials - Solutions for thermal decoupling - Calculating and designing venting processes - Targeted cooling and thermal conduction - Knowledge of sensors

Transporting Heat

Controlled Fluids
27 Stable Supply Systems
Physical and chemical specialist knowledge, highperformance simulation programs and a rened testing infrastructure are the requirements for developing components that work in uid environments. Automated production with highly productive and exible systems is a further challenge. Rchling Automotive offers its customers this specialist knowledge for both high-quality tanks and piping with extremely thin wall thicknesses. Fluid management also leads to other specialist elds when developing new drive systems.

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Expansion tank with level sensor made of conductive plastics

Expansion tank with ion exchanger for fuel cell vehicles

A cooling-water pipe with built-in mounts formed using projectile injection molding

Tanks
Multi-chamber solutions Controlled integrated ventilation Built-in level sensor Strong expertise in joining Guaranteed sealing, up to 40bar for extreme cases Highest purity grades Production under clean room conditions Integrated corrosion and scalding protection Solutions for shortened heat up time

Piping
- First series use of projectile injection molding for plastic pipes in the automotive industry - Consistent inner diameter - Benchmark for weight savings through reducible wall thicknesses - Minimal pressure drops - Generally enough standard materials - Homogenously structured inner surfaces

Fluid pipe by PIT

SPE-Award

Rapid prototyping

Laser welded oil tanks

Heated windshield washer uid module

Lightweight Structures
29 From Kilogram to Gram
Sustainable resources represent a central economic and ecological focus of the automotive industry. There is still much unrealized potential in the area of avoiding unnecessary materials as well as in substituting thick materials with thinner alternatives. The knowledge gained at Rchling Automotive through years of designing and producing lightweight applications is greeted with ever increasing demand. Sustainable applications are the object of intensive predevelopment work and are supported by the New Business Green Car development team.

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Battery tray in luggage compartment

Door module support made of plastic, coordinated to door panel and frame

Housings and Pans

- Structural and thermal protection for batteries - Airbag functions remain intact in crash situations - Larger pans come with optionally integrated material reinforcements - Highly automated processing of long glass bers - Compounded injection molding solutions for optimized strength in short glass ber reinforced components - Spare wheel trays in hybrid designs - Special solutions for spare tire storage

Lightweight Supports
- Weight reduction through substitution of metal solutions - Low warpage injection molding solutions - Many years of experience in back injecting and back foaming components - New composites with thermoplastic matrix - Varying porous reinforcement materials with low thicknesses for lightweight interior applications

Load-bearing interior oor made of STRATURA, thermally and acoustically insulating

Multifunctional tray for vehicle tool kits and more

Acoustic side panel with laminated lightweight reinforced materials

Material analyses in the scanning electron microscope

The World Is Our Home

Germany Mannheim Gernsbach Peine Wackersdorf Wolfsburg Worms Italy Abbiategrasso Laives Trento Volpiano Romania Pitesti Latvia Milzkalne Belgium Gijzegem Czech Republic Koprivnice Spain Araia

USA Duncan, SC Detroit, MI Akron, OH

China Changchun, Jilin Suzhou, Shanghai Chengdu, Sichuan

Brazil So Paulo Headquarters Research & Development Production

ny

Italy
Abbiategrasso Collegno Laives Laives Trento

Latvia
Milzkalne

eim ach adt

Czech Republic Further technical information by: Koprivnice

Further commercial information by:

Rchling Automotive AG & Co. KG Richard-Wagner-Strae 9 68165 Mannheim Germany Phone: +496 214 405 53 35 Fax: +496 214 405 53 55 E-Mail: info.sales@roechling-automotive.de

rsdorf urg

Spain
Araia

Rchling Gijzegem Automotive AG & Co. KG Flohafenstrae 40 67547 Worms Germany Phone: +496 2418 44118 Fax: +496 2418 443 16 E-Mail: info.engineering@roechling-automotive.de

Belgium

www.roechling.com