Scratch-resistant surface materials for the driver’s cab interior, oil and coolant hoses for high-temperature applications, and the new Continental air spring levelling system (CALS) are some of the new innovations from the technology leader ContiTech’s stable.
ContiTech company Benecke-Kaliko, one of the world’s leading producers of surface materials for passenger car interiors, is expanding into commercial vehicle range. All commercial vehicle activity – from light transporters to heavy trucks – is combined into a single segment. The current focus of the company is on the especially scratch-resistant materials TEPEO 2 Protect and DecoJect, amongst other products.
Commercial vehicles and buses are often exposed to harsh operating conditions. In order for the surfaces in the cab to look their best even after a long period of time, Benecke-Kaliko has developed materials with a special feature that elude sharp objects, generally making scratches a thing of the past.
The scratch resistance of the surface material TEPEO 2 Protect is based on a polymer material developed just for this purpose. It is additionally sealed with an extremely friction-resistant polyurethane varnish. This wards off the potential damage from frequent cleaning with normal cleaning agents.
The second scratch-resistant material is called DecoJect. Compared to painted injection-molded parts, it is a cost-efficient alternative and a real upgrade to the interior. The change in decor is very easy and many variable and diverse designs are available. The gloss level can be adjusted with the foil to match the interior. There are no limits when it comes to decorative prints and effect coatings.
Air spring levelling system
In the future, the new CALS from ContiTech will integrate the valve function for ventilation directly on the air spring board, as well as the pressure and ultrasonic height sensor. The wear-free and extremely precise ultrasonic height sensor implanted in the module will replace the mechanical height sensor, with rods prone to failure, which is currently predominant. The CALS allows significant weight savings of more than 3.5 kg on a truck with a trailing axle, and offers the vehicle manufacturer a plug-play module for more straightforward logistics processing and more efficient assembly on conveyor belts.
Lighter, more heat-resistant hose lines
Weight and thus also fuel savings is still one of the biggest challenges for the manufacturers of modern trucks. With the newest generation of oil and coolant hoses for high-temperature applications, aluminum-tube air-conditioning hose lines as well as a polyamide tube-hose combination for low pressure applications, ContiTech provides products that help manufacturers master these challenges.
The new generation of lightweight oil and coolant hoses is primarily used in the engine peripherals – for turbo-charger cooling and lubrication, engine cooling or exhaust gas recirculation. Previously where steel braided or Teflon hoses where applied, ContiTech now uses very lightweight rubber hoses that have been adapted to the increasing temperatures in the engine environment. The coolant hoses are designed for temperatures of up to 190°C, for a short time even up to 210°C, while the oil hoses manage with a continuous temperature exposure of up to 230°C, even up to 250°C for a short time.
In addition, these particularly media-resistant hoses are more flexible than previous hoses, enabling various hose installations through pre-forming, if necessary.
When it comes to air conditioning lines, ContiTech presents the reliable air conditioning hose, which, in combination with aluminum tube elbows, provides a weight-saving hose line. The polyamide tube-hose combination developed by ContiTech for low pressure applications in the constantly growing PA product portfolio also follows the trend towards weight and cost savings. ContiTech profits here from the process competence that the Fluid Technology business unit has appropriated in the area of synthetic material production.
Futuristic hose lines
Also, a topic for the future, which ContiTech is already paying attention to today, is the recovery of exhaust heat called waste heat recovery. This involves using the exhaust heat to heat an additional medium and feeding the resulting gas into the engine to assist the motor and thereby optimize fuel consumption. ContiTech is already developing hose lines especially for this application.
Dual fuel, the combined injection of gas and diesel fuels, is another topic for the future that ContiTech is currently working on. The newest generation of fuel hoses provides the ideal basis for this and can be developed further in this direction.
The new elastomer fuel lines from ContiTech have been adapted to the increasing pressures and temperatures of truck engine compartments as well. They are currently stable up to an operating pressure of 35 bar and temperatures of up to 135°C, and an increase of these parameters is currently being tested at ContiTech.
The emerging trend, primarily in Europe and North America, of also using alternative fuels in trucks is supported by ContiTech with hose tubes for gases like CNG and LNG. So when it comes to lines for all media flow types in trucks, truck manufacturers are optimally equipped with solutions from ContiTech for current and future challenges in the industry.