A new lightweight and airtight air duct, designed for immediate use in commercial vehicles, has been successfully developed by a research team in South Korea. This domestically produced air duct is expected to replace the current French-made versions, enhancing the self-sufficiency of the country’s automotive industry and contributing to significant advancements in vehicle performance and safety.
The development, led by Senior Researcher Seunghoon Bae at the Busan Machinery Research Center of the Korea Institute of Machinery and Materials (KIMM), was a collaborative effort involving Yujin SMRC Automotive Tech Co., Ltd. (Yujin SMRC A.T.) and SH Korea. The new technology has successfully passed performance evaluations for completed vehicles and is now on the verge of commercialization. It represents a breakthrough in air duct manufacturing for automotive cockpit modules.
Enhanced Design and Manufacturing Process
The newly developed air duct, made using foam sheets, achieves a weight reduction of approximately 60% compared to traditional high-density polyethylene (HDPE) ducts. This innovation not only reduces the weight but also addresses key issues like poor insulation, noise generation, and safety risks associated with older models. The new duct offers improved thermal insulation, noise reduction, and enhanced fuel efficiency, leading to a more comfortable and safer driving experience.
The advanced manufacturing process, which utilizes vacuum forming and a hot knife technique, allows for the precise production of complex shapes, significantly reducing defect rates compared to conventional blow molding. This method also boosts productivity, further contributing to the competitiveness of the product.
Future Applications and Market Expansion
Following rigorous testing and performance evaluations, the research team confirmed that the new air duct meets the necessary specifications for automotive applications. The team also developed techniques to assess the dynamic properties of polymeric materials, enhancing the reliability of the product.
Senior Researcher Seunghoon Bae stated that the new air duct addresses the shortcomings of previous models and is expected to be applicable to a wide range of vehicle types. Sungbin Lim, Head of the Research Lab at Yujin SMRC A.T., expressed confidence in the component’s quality, cost efficiency, and potential for weight reduction, with plans for mass production to increase competitiveness both domestically and internationally.
