Innovation, research and development

Bosal’s research and development center has continued to add innovations to the three core concepts in exhaust system design which will make significant reductions in tailpipe emissions by either saving weight (therefore cutting fuel consumption) or by improving the after-treatment of exhaust gases.

These concepts span the entire exhaust system from cylinder head to tailpipe including Manifold, Catalytic, Converter and Hanger Systems. The Manicat is a fabricated insulated exhaust manifold which features an integrated starter catalyst. Another innovation is the Lightweight Exhaust, which redefines from first principles the design, manufacture and installation of the entire exhaust system.

Bosal Delphi Complete Exhaust Systems

Bosal Delphi Complete Exhaust Systems is a non-equity based alliance between one of the world’s largest Tier I suppliers and one of the world’s leading manufacturers of exhaust systems. This unique alliance offers complete exhaust systems for vehicle manufacturers worldwide. Delphi has extensive experience and resources in the design and manufacture of the exhaust system “hot end,” or front exhaust module, including gas and diesel catalytic converters, catalysts, and exhaust manifolds. Bosal is recognized as a leader in the design and development of the “cold end,” or rear exhaust module, including mufflers, resonators, and tailpipes. Together, Bosal and Delphi offer the facilities and resources to develop complete exhaust systems that can be tailored to individual customer needs and help meet current and future emission and acoustic requirements.

Bosal Delphi Complete Exhaust Systems offers a complete system that is durable and cost-effective. A complete exhaust system includes:

    • Catalytic converter
    • Exhaust manifolds
    • Muffler
    • Resonator
    • Tailpipe/exhaust tip
    • Connection pipes
    • Hangers, brackets, and isolators

Typical Applications

Bosal Delphi Complete Exhaust Systems offers customized exhaust systems for automotive and commercial vehicle manufacturers worldwide to help them meet increasingly stringent emission standards and to help reduce engine sound for the benefit of vehicle occupants and pedestrians.

Performance Advantages

Bosal Delphi Complete Exhaust Systems optimizes the development of a complete exhaust system by leveraging the expertise of two world leaders of exhaust system technology. Blending Delphi’s extensive catalytic converter expertise with innovative Bosal technology such as the Lightweight Exhaust System, the Bosal Delphi alliance offers vehicle manufacturers around the world durable, lightweight complete systems. Research and development times can be reduced, while reduced infrastructure costs help make the system more cost-effective. The Bosal Delphi team can offer customers:

    • Complete systems weighing 30-50 percent less than conventional 409 stainless
       steel systems
    • Industry leading converter durability performance
    • Fragile substrate canning capability
    • Access to engine management systems controls expertise and algorithms
    • Full computer-aided engineering (CAE) capability
    • Worldwide validation capability
    • Emission technology support
    • Acoustics treatment optimized for sound level, performance, and cost
 

The Bosal Delphi alliance allows current customers to maintain existing relationships, while future customers can develop a complete system through a single point of contact. Cost-effective manufacturing techniques coupled with global technical center and manufacturing locations enable Bosal Delphi Complete Exhaust Systems to meet customer requirements quickly and efficiently. The team offers customers:

    • A single point contact
    • A global technical and manufacturing presence
    • Program management to help meet program objectives—on time
    • Compatibility with nearly any computer aided engineering system
    • Worldwide engine, bench, and vehicle test facilities
        - Mechanical, chemical, and thermal aging and performance tests
        - Acoustic analysis and performance tests
    • Design documentation and release capability using customer protocols
    • Engine management system design skill applied to aftertreatment architecture