The production of air ducts in a twinsheet thermoforming process using cross-linked PE foam was invented by Trocellen and has proven itself as technically and commercially attractive alternative to the traditional air ducts made by extrusion blow-moulding of polypropylene (PP).
Trocellen’s distinguished knowhow and in-depth customer support regarding optimal material choice and process parameters in combination with the company’s perfectly suited chemically cross-linked PE foams have made Trocellen the preferred partner for manufacturers of serial twinsheet air ducts as well as car manufacturers.
The PE foam can be thermoformed into complex geometries and air ducts for diverse application areas within the vehicle such as instrument panel, pillars, floor and roof can be realised. The possibility to include reinforcement ribs, different fixation methods and other individual solutions allow the construction of air ducts meeting high demands.
Due to the properties of the closed-cell PE foam the air ducts show excellent advantages compared to rigid plastic ducts:
Trocellen PE foam air ducts are already used in different car application areas by various car manufacturers:
|Parameter||Thermoformed soft, flexible duct||Extrusion blow-moulded rigid, stiff duct|
|Material||XLPE foam ¹||PP solid|
|Weight reduction||up to 65% lighter||– (compact material)|
less energy loss:
efficient use of AC,
better noise absorption,
less ventilation noise
|Assembly / Installation||+
good sealing function
difficult (stiff), additional sealings required
|Squeak & Rattle||+
squeak & rattle minimised
even in tight spaces
|Heat resistance (° C)||-30/+105||-30/+120|
|Burning rate (FMVSS 302)||< 100 mm/min||< 100 mm/min|