Exhaust Systems

A Sophisticated Balance of
Competing Requirements

Exhaust Systems

Products

Exhaust Systems

Purpose:
We provide products that meet regulations in each country and are optimized to the needs of the market. Our products fulfill competing requirements such as improving fuel consumption so as to reduce environmental burden through improving exhaust gas purification and reducing weight; achieving engine performance; and having a pleasant exhaust sound.

Strengths:
The development and production of exhaust total systems requires the use of different types of prediction techniques and the conduct of physical verification at test centers in order to achieve a sophisticated balance. Our products are made based on Calsonic Kansei’s production system, and are highly rated by automotive manufacturers around the world.

Exhaust Systems

Exhaust System

Exhaust SystemsExhaust System

Exhaust System

Purpose:
We develop and produce the entire exhaust system starting from exhaust manifolds to meet the needs in engine performance, fuel consumption, and sound for different regions such as North America, Asia, and Europe.

Strengths:
By using a double-wall structure for our exhaust manifold, we were able to make the wall of the inner pipe thinner gauge material to reduce its thermal mass, thereby accelerating the rise in temperature of the catalyst to improve its emission performance.
For exhaust systems, we adopt a dual structure to achieve higher power and fuel efficiency with backpressure reduction. A lightweight system is achieved by using spun mufflers and welding mufflers.

Muffler

Exhaust SystemsMuffler

Muffler

Purpose:
Engines generate exhaust sounds and high-temperature exhaust gases. Mufflers use their internal structure to reduce the exhaust sounds and cool the high-temperature exhaust gas.

Strengths:
We use sound simulation to optimize the internal structure of mufflers so as to create sounds according to the required needs. We also reduced the number of components used in our mufflers, and use appropriate materials to meet the market requirements of each region. We meet our customers’ wide range of needs with our lineup of world-leading lightweight welding mufflers, stamped mufflers, and spun mufflers, using deep drawing stamping technology and thin welding technology with thinner gauge materials.

Exhaust Manifold Converter

Exhaust SystemsExhaust Manifold Converter

Exhaust Manifold Converter

Purpose:
This product collects the exhaust gas of a multi-cylinder engine, leading the gas into the total exhaust system, and purifies harmful substances generated by the engine.

Strengths:
In exhaust manifolds, the difference in shapes, such as port length and confluent section, can interfere with the exhaust gas and affect the exhaust gas’s contact with the catalyst. Using thermal and fluid analysis of these characteristics and through material selection, we derive the most appropriate shape during our product design so as to improve engine power and purification performance.
To improve the speed of temperature rise so as to accelerate reaction with the catalyst, we reduce thermal mass of the different components by using thinner gauge material that can be used in high-temperature range.

Spun Converter

Exhaust SystemsSpun Converter

Spun Converter

Purpose:
Compared to the traditional casing, we have reduced the number of components and weight of our spun converters, which in recent years have been widely used as lightweight cases for catalysts, and also as mufflers.

Strengths:
By using a structure that retains the entire catalyst surface mat support, the mat functions as an insulating material. In addition, it is filled with glass wool which functions as the sound absorbing element. This reduces the surface temperature of the casing, and allows it to be used without the need for an insulator. We use the thinnest gauge of 1.0 mm.

Flexible Tube

Exhaust SystemsFlexible Tube

Flexible Tube

Purpose:
Flexible tubes are installed in exhaust systems to absorb engine vibration that is being transmitted to the exhaust system. This improves the strength of the exhaust system, and reduces vibration being transmitted from the hanger to the vehicle body.

Strengths:
We adopt an interlocking structure, and the insulating effect allows us to make the walls thinner. This allows us to achieve an improvement in vibration absorption capability and lighter weight.
We offer flexible tubes with diameters and lengths appropriate to the vibration characteristics of different exhaust systems.

Control Valve

Exhaust SystemsControl Valve

Control Valve

Purpose:
These are mounted inside mufflers. By using the difference in pressure within the exhaust system controlled through the opening and closing of the valve, they help to reduce the muffler’s backpressure and improve noise reduction.

Strengths:
We have small and lightweight valves used mainly with small- to medium-sized engines, and also two-stage variable valves for low backpressure systems. We are able to meet a wide range of sound and engine performance needs by using different configurations of valve types and valve operations.
This allows mufflers to be made smaller, thereby increasing the spaces of cabins and trunks, and also contributes towards weight reduction.