Next-generation oil module ramps up plastic content

Mann-Hummel has maximized the use of plastic in an oil module it makes for Audi’s 2.0 L, four-cylinder FSI direct-injection engine. The module is more than 85% plastic by weight, providing a weight savings of about 20% in comparison to a conventional aluminum housing. Bayer supplies the glass-filled nylon used in the module. The only metal components in the module are an aluminum oil cooler and metal inserts and valves.
Mann-Hummel vice president of engineering for liquid filter systems, Kai Knickmann, presented a paper on the module at the recent Society of Automotive Engineers World Congress in Detroit.
In addition to lower weight, the module offers improved functionality and 20% lower cost. Knickmann said the replacement of a die-cast aluminum housing with one made entirely of plastic was a result of the development of high-temperature plastics, modern production processes and simulation techniques.
Injection-molded plastic modules are cheaper to produce than die-cast modules because the part doesn’t require any finishing operations such as drilling, milling, etc. Knickmann noted that not all engine designs are compatible with plastic oil modules; especially engines calling for the module to be located on the exhaust side.
"You need to take into account how much effort is needed to make some heat shields, and decide whether it is worth it."