Technology

Technology


Remain-Core Molding


Remain Core Molding

Commercial production of the first resin Intake Manifold in Japan

Remain Core Molding technology, which is the combination of blow molding and injection molding, was pioneered by EXCELL.

A traditional metal intake manifold such as aluminum is resinified by using Remain Core technology. Excell was the first company to mass produce a resin intake manifold in Japan.

Remain Core Molding Process

The inner core is formed by blow molding with functional parts, such as a flange, being formed by low-pressure injection molding around the blow molded inner core.

The blow molded core has a non-reinforced nylon layer which reduces inner air flow resistance. The mechanical strength is maintained by molding glass fiber reinforced nylon around this inner core.

45% GF reinforced Nylon 6 / 30% GF reinforced Nylon 6 / Non-reinforced Nylon
Inner Core: Blow Molding (air path forming) / Outer layer: Low-pressure Injection Molding (adding function and rigidity)

Manufacturing Process of Remain-Core

Blow Molding → Low-pressure Injection Molding → Cutting Work → Assembly Process

As seen above, highly functional products are produced in a very simple manufacturing process.

Blow Molding
Low-pressure Injection Molding
Cutting Work
Assembly Process

Intake Manifold by Remain-Core Molding Process 01

Weight Reduction, Noise Reduction, Cost Reduction, High Reliability

30% of weight is reduced by resinification of metal parts.
Remain-Core method is formed with multiple layer of resins therefore high noise reduction performance is achieved by acoustic characteristics of resin materials and their combination.
Its sound transmission loss quality is the same as aluminum.

Strength and reliability are high because outer part of Blow Molded product is completely covered by Injection Molding layer.

Intake Manifold (Blow + Low-pressure Injection Molding) 3 layers (PA6+PA6-GF30%+PA6-GF45%) SUBARU: SAMBER DIAS (lightweight truck)
Intake Manifold (Blow + Low-pressure Injection Molding) 3 layers (PA6+PA6-GF30%+PA6-GF45%) SUBARU: SAMBER DIAS (lightweight truck)
Intake Manifold (Blow + Low-pressure Injection Molding) 3 layers (PA6+PA6-GF30%+PA6-GF45%) SUBARU: SAMBER DIAS (lightweight truck)

Intake Manifold by Remain-Core Molding Process 02

Design based on commercial production experience with heavy duty engines using super chargers, this application has been adopted for automobile use.

The complicated intake manifold of horizontally opposed engine is resinified by Remain-Core molding.

[1] Blow Molded Inner Core/ [2] Injection Molded Part
[3] Fitting harnesses and other parts / [4] Mount onto SUBARU LEGACY