The new Chevrolet LT1 Camaro SS is using an injection molded separator to keep liquid oil from travelling up filtered air systems into the vehicle’s intake systems during high acceleration.
The oil is returned to the oil pan, improving performance and reducing oil consumption.
The device is interesting from a manufacturing perspective.
First, it uses a materials technology from DuPont called Shield that is designed to preserve mechanical properties at elevated temperatures. Shield is based on a premium heat stabilized, glass-reinforced polyamide 6/6. Applications include engine covers and oil pan gaskets. The specific grade in the Camaro air/oil separator (AOS) is Zytel PLS95G35DH1.
Vibration welding is used to attach the PCV plate and the cover plate. The connector is spin welded. The molder is ElringKlinger North America, which operates a plant in Buford, Georgia.
The device is also used on the LT4 CTS-V model. An AOS device on the Porsche Boxer uses a different manufacturing technology. Air/oil separator failures on the Boxer can generate what owners call “great smoke bombs”.
The Camaro separator was a finalist in the 2015 Society of Plastics Engineers (SPE) Automotive Innovation competition.