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Mann & Hummel redesigns air intake plenum for BMW

Mann & Hummel is supplying the intake plenum for the first 8-cylinder engine in the new M3 sports car from BMW. The plenum, forming part of the flow-optimised air intake system, reinforces the spontaneous response of the high performance power unit.

In addition, the concept opens up new possibilities in engine compartment design. A patent has been filed for this concept.

The company says that the dimensions of the intake plenum are different from conventional designs, which provide 0.5 to 3 times the engine displacement in current passenger cars. With a 28 litre volume, the plenum ensures that the required quantity of intake air is available under all operating conditions for the 309 kW (420 bhp) 4 litre 8-cylinder engine.

The part, made from polyamide 6 with 30 per cent glass fibre content, weighs only 5kg. It thus also helps to optimise the weight of the high performance engine, which amounts to just 202 kg.

Mann & Hummel has developed a new concept specifically for this component that effectively conceals weld seams. This provides engine compartment designers with opportunities to shape the immediately visible surfaces of the intake plenum to meet specific requirements. The circular weld seam at the contact point of the two shells was previously considered to be unavoidable. This greatly limited the use of vibration welding for premium styling parts.

The new concept, for which a patent has been filed, removes this troublesome weld seam for styling parts. Vibration welding can thus now also be used to meet even the most demanding visual specifications.

Series production of the intake plenum, began in April 2007, with production volume of around 20,000 per annum.

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