Less Fuel. More Drive.Röchling Automotive Profile

Benefits for Customers Across the Globe

The Röchling Group, established in 1822, has operated in the field of plastics processing for over 90 years. Our globally positioned group of small and medium-sized companies is characterized by its innovative applica-tions 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 benefit from global standards as well as the power of a strong group.

Röchling Automotive aims to provide vehicle manufac-turers and their customers with future-oriented techno-

logy in the fields of air flow 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.

Get There Quickly with Röchling

Competence. Quality. Innovation.

Competence: Air Flow Management

Directing the Flow

On Point: Quickly and Efficiently

- Optimized engine performance with the help of aero-dynamic flow simulations (CFx) in single and multi-channel systems

- Reduced weight by integrating the charge-air cooler in the intake manifold, simplifying component designs and substituting metals

- Reduced resistance through intelligent air flow 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 benefit by taking a holistic approach to development and validation

Competence: Acoustics

Bringing Silence to Life

Pitch Perfect

- Integrated acoustic features in lightweight materials

- Noise damping and absorbing components for under-bodies, engine compartments and passenger compart-ments

- Engine simulations with GT Power for that extra performance boost and customer-specific intake acoustics

- Sound designs with or without low and high-frequency resonators

- Acoustic and aeroacoustic calculations for both far and near-field 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

0807

System: Engine Air Intake

Less Weight, More Performance

Simulate Reality AccuratelyThere 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 system‘s individual components. Strong in the details, yet remaining flexible: That‘s how Röchling Automotive has made a name for itself as a system supplier.

Campbell diagram before and after acoustic optimization

Tracking down pressure losses Determining air flow speeds

A new topology of the intake section, with the charge-air 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.

Downsizing by Integration

Intake section, developed and produced by Röchling Automotive

Air filter housing made from 99 percent Plantura biopolymers

1009

Air filter cartridges manufactured in-house Optimizing acoustics Air flow analysis

- Great range of vertical manufacturing and flexibility from producing our own paper filters

- Fleece filters for greater durability and improved filtration results

- Various pre-filtration designs - Maximized filter dust capacities through optimal

particle distribution - Forecasted filter service life - Quick presentation and evaluation of options due to

high-performance system development

- 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

Reliability Starts with the Filter

Air Filtration Sound Design

The Art of CoordinationIntake systems are characterized by excellent filtration, 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 filters to multi-level filtration designs: The air flow management and acoustic expertise of the developer represents a benefit to the customer. As do the various manufacturing techniques. The end result is satisfied drivers pleased with their vehicles‘ low maintenance costs, driving enjoyment, and great sound. The environment also benefits from the quieter outlet noise.

High performance solutions for sports cars

Air filter – Twins for the premium class

Functionally optimized air filter housing Radiation cross-linked clean air tube with Helmholtz resonator

1211

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

- Flexible piping using one-component and two- component blow molding technology

- Resistant to aggressive substances - Plastic return pipes for temperatures up to 230°C - Mounting elements attached with high cohesiveness

thanks to Jectbonding™ - Intelligent injection molding solutions - Unique test stands and validation facilities

- Built-in shifting mechanisms and flaps - Charge-air cooler integrated in the intake manifold - Multi-channel solutions - Optimized and harmonized air flows thanks to high-

performance software - Constructed according to acoustic requirements - Comprehensive testing technology - Joining shell over injection

Intake ManifoldsCharge-air Tubes

From Turbo to Combustion Chamber

Two-channel intake manifold

SPE-Award

Pre-intercooler duct, up to 230°C

Pressure in the SystemAir tubes and intake manifolds are designed almost completely digitally. This greatly aids in ensuring that high temperatures combined with major fluctuations in pressure do not lead to mechanical failure – even after extensive periods of operation. To accomplish this, air flows, 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 high-performance engines, from compact cars to luxury sport sedans.

Precision is our focus Intake manifold, made in PolypropylenJoining by overinjection

1413

Thermoacoustic Engine Encapsulation

Engine Isolation on the Sides-- Various-approaches-for-sound-absorption-- Thermally-insulating-materials-- Temperature-resistant-lightweight-construction-

Composite-materials-- Full-body-and-partially-placed-aluminum-heat-shields-

for-lightweight-reinforcement-materials-- Blow-molded-solutions-- Integrated-seals-and-brackets

Databases-holding-characteristic-values-collected-from-our-acoustics- laboratory-help- in-design-planning.-Ther-mal- imaging- data- provides- insights- into- the- thermal-loads- of- various- components.- Thermal- conductivity-values-are-crucial-for-heat-dissipation-and-thermal-isola-tion.-Every-design-is-custom-tailored-to-meet-customers‘-specific-needs.

-- 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-filled-plastics-- Solutions-with-or-without-foam-absorbers-- Broad-spectrum-of-manufacturing-approaches

Partition walls

Sound and EnergyWith- clever- engineering,- engine- noise- emissions- can-be- brought- to- lower- levels- without- having- to- sacrifice-much-installation-space.-The-keyword-here-is-acoustic-integration-in-lightweight-construction-materials.-Here,-Röchling- Automotive- offers- a- unique- spectrum- of-various-material-and-production-approaches.

Engine-side-second-front-wall,-sound-insulating Second-firewall,-sound-absorbing

CO2-management:-Thermoacoustic-insulation

Heat-stays-in-the-engine-compartment-with-encapsulation

Drive-by-sound-level-measurement Engine-compartment-–-Partition-wall-made-with-SMC Thermal-imaging-data

1615 Less CO2

Benefit-for-the-customer:-many-aerodynamic-advantages-as-well-as-engines-that-warm-up-faster-and-stay-warm-longer.- Röchling- Automotive- develops- and- validates-component-designs-for-customers-throughout-the-entire-world:- For- both- passenger- and- commercial- vehicles- –-independent-of-the-drive-system.

Smart Cooling Air Controls

Controlled Shutter Systems

Competence: Actuators

-- Improved-drag-coefficient-- 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

-- Complete-solutions-- Customer-specific-validation,-wind-tunnel-testing,-

LIN-conformity-tests-and-error-diagnostics-within-the-vehicle-using-vector-software

-- Integrated-FailSafe-functionality

Controllable- air- flap- systems- lower- fuel- consumption-and- CO2- emissions.- One- reason- for- this- is- reduced- air-resistance- with- the- flaps- closed.- These- flaps- close- or-remain-closed-when-greater-cooling-capacities-are-not-needed- or- desired.- The- movement- of- the- air- flaps- is-usually-controlled-with-a-sophisticated-actuator-system.

Open-/-closed-according-to-customer-wishes Active-air-flap-system

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

Modules-with-multiple-rows-of-flaps,-centrally-controlled

Deflectors-for-further-optimization-of-aerodynamics Deflector-frames-with-up-to-99-percent-organic-materialActuator-development-

Flap-open

Air high-cooling-capacity

Flap-shut

improved-aerodynamics

Radiator-grill unprotected protected

Cold-start normal accelerated

Interior/glass warms-up-normally accelerated-warm-up

Noise-level normal lower

1817

Aeroacoustics for the Interior

-- 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

Detailed- flow- analysis,- advanced- manufacturing- tech-nology,-and-acoustically-effective-lightweight-construc-tion- materials- represent- the- foundation- for- product-ideas-that-make-driving-more-enjoyable.-Special-measu-ring-techniques-and-testing-methods-round-out-the-ser-vice-offer.

Air/Water Separation Climate Control-- Flow-analyses-for-individual-components-and--

complete-systems-- Optimized-flows-- Minimal-loss-of-pressure-- Absorbing-materials-- Thermally-insulating-materials-- Integrated-switch-flaps

More ComfortPassengers- of- vehicles- with- Röchling- Automotive-products- should- travel- with- peace- of- mind.- Con-sidering- the- effective- separation- of- air- and- water,-optimized-channel-air-flow,-and-noise-reducing-meas-ures,-innovation-is-redefining-the-state-of-the-art.

Windshield-cowl-with-integrated-pedestrian-impact-protectionHollow-profile-soft-seals-produced-using-projectile-injection-technology

SPE-Award

Acoustic-climate-channels-made-of-lightweight-materials

Seals-are-mechanically-and-acoustically-optimized Acoustically-effective-housings-for-A/C-units

Air-intake-with-filter

Complete-air-distribution-system

Competence: Lightweight Construction

Developing Top-class Models

-- Acoustic-lightweight-construction-using-multi-layered-material-compositions

-- Perfect- balance- of- strength- and- stiffness- using-targeted- fiber-alignments-and-optimized-fiber/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

Save Weight without Sacrificing Safety

2221

System: Underbodies

Light, Acoustically Active Absorption SurfacesVehicle-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.-Röchling-Automotive-sup-ports- this- efforts- through- extremely- light- composite-materials-with-various-porous-cores-and-coatings.-

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.

Lightweight Design, Solid Performance

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,-Röchling-Automotive-offers-its-customers-high-temperature-resistant-underbody-materials-–-a-novelty-that-enhances-integration-in-the-vehicle-floor.

High-temperature Solutions

Modularly-constructed-underbodyLightweight-underbody-with-textile-and-injection-molded-wheel-arch-liners

Aero-acoustic-underbody-with-molded-cooling-channels-and-large-surface-perforated-aluminum-foils-applied

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

without underbody

Hard plastic underbody + additional absorber on the upper side

Seeberlite 2

dB

Hz31,530

40

50

60

100 315 1k 3,15k 10k

overall level [dBA]

69.168.568.1

23 24

Working Together to Reduce Emissions

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

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

Functionality in Tight SpacesThe- product- solutions- developed- for- our- customers-around- the- world- need- to- conform- to- various- speci-fications.-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,-flammability-properties,-and-temperature-stability.

Chipping-resistant-engine-undershieldcomes-in-various-models

Side-body-undershields-with-area-densities-of--less-than-1,000-g/m²

Exhaust-system-cover-with-cool-air-openings-molded-into-the-material

Textile-wheel-arch-liner

Insulator-in-D-LFT-with-built-in-maintenance-flap Preparations-for-vehicle-testing 2-component-solutions

weight per area

glass content tensile stregth

tensile E-module

thickness (compact grouted)

thickness (acoustically)

Seeberlite DLFT

Competence: Thermal Management

Transporting Heat

-- 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

Because All Energy Is Useful

27 28

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

Controlled Fluids

-- 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

Tanks

Stable Supply SystemsPhysical- and- chemical- specialist- knowledge,- high-performance-simulation-programs-and-a-refined-testing-infrastructure-are-the-requirements-for-developing-com-ponents- that- work- in- fluid- environments.- Automated-production-with-highly-productive-and-flexible-systems-is-a-further-challenge.

Röchling-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- fields- when- developing- new-drive-systems.

SPE-Award

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

Rapid-prototyping Laser-welded-oil-tanks- Heated-windshield-washer-fluid-module

Fluid-pipe-by-PIT

29 30

Lightweight Structures

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

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-fibers-- Compounded-injection-molding-solutions-for-

optimized-strength-in-short-glass-fiber-reinforced-components

-- Spare-wheel-trays-in-hybrid-designs-- Special-solutions-for-spare-tire-storage

From Kilogram to GramSustainable- 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-Röchling-Automotive-through-years- of- designing- and- producing- lightweight- appli-cations- is- greeted- with- ever- increasing- demand.-Sustainable-applications-are-the-object-of-intensive-pre-development- work- and- are- supported- by- the- New-Business-Green-Car-development-team.

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

Acoustic-side-panel-with-laminated-lightweight-reinforced-materials-Multifunctional-tray-for-vehicle-tool-kits-and-more

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

Material-analyses-in-the-scanning-electron-microscope

Battery-tray-in-luggage-compartment

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www.roechling.com

Further commercial information by: Röchling Automotive AG & Co. KG Richard-Wagner-Straße 968165 MannheimGermany-Phone : + 49 621 440 55 – 335Fax : + 49 621 440 55 – 355E-Mail: info.sales@roechling-automotive.de

Further technical information by: Röchling Automotive AG & Co. KG Floßhafenstraße 40 67547 WormsGermany Phone : + 49 6241 844 – 118Fax : + 49 6241 844 – 316E-Mail: info.engineering@roechling-automotive.de