Trocellen PE foam air ducts

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).

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.

Learn more about twinsheet thermoforming process here. 

Advantages

• Weight reduction – up to 65 % lighter than solid air ducts
• Thermal insulation improvement – reduction of energy loss 
• Acoustic absorption - up to 5 dB less airflow noise
• Sealing function - no squeak & rattle 
• No condensation – no bacteria   
• Odourless material – no smell, no fogging
• Easy production process – thermoforming and cutting 
• Easy assembly – high flexibility, good restoring behaviour
• Easy prototyping - cost-efficient prototype tools and fast prototype production 

Trocellen PE foam air ducts in serial production

Trocellen PE foam air ducts are already used in different car application areas by various car manufacturers:

Comparison Matrix – soft PE foam vs. rigid PP air ducts

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