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Forum LockedSecond Generation Fully Plastic Oil Filter Module Debuts in BMW

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    Posted: 11-March-2009 at 21:25

Second Generation Fully Plastic Oil Filter Module Debuts in BMW Six-Cylinder Diesel Engine

2009-03-10 - Five years after start of production of the first fully plastic oil filter module, Mann+Hummel is launching the second generation into the market. The first series production of this module has now started, for installation in the new BMW six-cylinder in-line diesel engine. It is characterised by a high degree of functional integration and offers substantial weight and cost benefits, compared with conventional oil filter modules containing die-cast aluminium housings.

The oil filter module contains a metal-free filter element with an anti-drain valve on the lower end disc, a centre tube with integrated filter by-pass valve as well as an oil-water heat exchanger integrated into the housing which can be by-passed under extreme operating conditions through activation of an in-built valve. Integrating the oil cooler by-pass valve in the heat exchanger offers an advantage, compared with conventional designs: there is only one sealing surface between the housing and the heat exchanger. To seal the flange, the German supplier has for the first time used metal-elastomer bonded frame sealing.

The Ludwigsburg-based company has specifically developed a filter element for the new plastic oil module with an integrated silicone anti-drain valve which has an opening pressure of well under 0.1 bar. A patent has been filed for this component, which substantially reduces pressure loss in the oil module and prevents the oil from leaving the feed line when the engine is switched off, ensuring pressure is quickly restored on re-start. A consistent supply of oil is maintained to all engine components requiring lubrication and cooling.

The supplier applied the latest computer-aided engineering-based development methods to design the plastic housing, utilising experience gained over many years in the production of plastic oil filter housings. A consistently low differential pressure in the oil module is ensured by optimum channel arrangement and improved inflow to the filter element. Another key feature is uniform wall thickness, making it possible to reduce weight.

The design engineers selected for the housing high-temperature resistant polyamide 6.6 with 35 percent glass fibre content. The team of experts from the development and production departments used computer-aided simulation to confirm that the required strength and low deformation values, particularly in the seal areas, were achieved. On this basis, the type of plastic was selected and the tooling concept established for the injection moulding process.

Mann+Hummel relies on its development experience accumulated over many years, and also on its specific production technology for plastic oil modules which are already in series production. The development partner and original equipment supplier to the international automotive industry is now applying this knowledge to produce the first fully plastic oil filter module to be supplied to BMW. The company is extending its concepts regarding functional integration to offer flexible solutions within tight packaging constraints.

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