| Summary: |
The world's first continuously variable intake manifold
using a glass fiber-reinforced phenolic to mold complex geometries of the
functional elements. Weight
savings: 20-25% over aluminum. |
| Most Innovative Feature: |
Unlike other systems which - by some kind of flaps - have
just an on/off functionality this manifold is the world's first continuously
variable intake manifold. As a completely new development, this is the
initial implementation of the concept of ideal adaptation of the lengths
of the ports to the desired engine speed characteristics (Torque, engine
output). The determining factors in the selection of glass fiber-reinforced
Duroplast for the functional elements were the mouldability of complex
geometries and the dimensional stability of the phenol resin under diverse
kinds of load. |
| Other Innovative Features: |
N/A. |
| What Forming Process? |
Injection Molding Thermosetting. |
| First Time Process Used: |
Yes, regarding the complex components. |
| Previous Process: |
Principle of continuously variable runners used for the
first time, other manifold systems use flaps usually made out of
thermoplastics. |
| Tooling Innovations: |
High quality tool steels, best surface coatings, special
tool technology to form the window in the runner, fully automatic
concatenated manufacturing process, internal pressure monitoring in the
tool, special cool/calibrating equipment. |
| New Material Developments: |
Material optimized to ensure the mouldability of the
complex geometries under adherence to stringent tolerances and to meet the
dimensional stability of its phenolic composite components under
temperature, mechanical and chemical load. |
| Weight Savings: |
Approximately 20 to 25% over aluminum. |
| Cost Savings: |
Principle of continuously variable runners used for the
first time, no suitable comparison possible. |
| Cost Avoidance: |
Using phenolics helped reducing development time / costs by
early availability of production parts. |
| Direct Consumer Benefit: |
The fully-variable intake system has enabled the realization
of ambitious goals as regards torque and power output. |
| Translates to Other Vehicles?: |
This particular application just fits the engine it was
designed with. Together with the engine it can be translated to
other vehicle lines. And its principle can be translated to other
engines/OEM's, too. |
| Safety Benefits: |
Overpressure hazards are addressed through manifold design
(hybrid system) and material choice without additional components. |
| Environmental Benefits: |
Reduced weight and improved fuel economy reduce engine's
environmental impact. |
| Additional Comments: |
A demanding concept has been developed into a
high-performance product within a short period of time. Together with
further innovations in the new BMW eight-cylinder V engine, this has led
to the creation of an inspiring major assembly. The fully-variable intake
system has enabled the realization of ambitious goals as regards torque
and power output. |
