Conti, aft automotive awarded for synthetic coupling system

HANOVER, Germany—Looking to the future of mobility, Continental A.G. and aft automotive GmbH have combined their design expertise to produce a modular coupling system for heat management in both internal combustion engine and electric vehicles.

The innovative design of the synthetic coupler cuts down on overall materials used in production, weight and improves flow. A lighter weight to a coupling system means less fuel is used and less CO2 is produced by the vehicle, especially in internal combustion engines. And fewer materials needed in production of the parts means less CO2 is produced during manufacturing.

It was that sustainability that garnered Conti and aft automotive—a joint partnership known as JoinPlas—a Materialica Design and Technology Award from the judges at the eMove360° Hybrid International Trade Show, conducted recently in Munich.

"We are absolutely delighted with this award," said Arndt Nikolaus, Continental partner in the newly established joint venture. "It is an affirmation for the entire team that worked tirelessly on this development. Pooling and sharing our know-how in order to drive the future of automotive lines is a further major milestone in our partnership."

According to aft automotive, based in Greven, Germany, and Conti, the polypropylene (a mixture of rubber, polyamides and aluminum materials) coupling system saves 15 percent in materials.

According to the joint venture, with previous coupling systems each variant required a dedicated injection mold. That meant a lot of couplers for the auto industry. More importantly, it meant high design, tool making and process validation costs.

The modular coupling system needs only two tools per diameter.

"The connection angle can be varied, and all the production steps can be fully automatically monitored using a camera," JoinPlas said in a statement.

The companies claim the synthetic coupling system also boasts improved performance, with minimized pressure losses in the transfer area.

"This CO2-efficient solution shows the way for future mobility," the judges stated in awarding the Materialica Award. "That is because the coupling system does not just cut CO2 emissions in operation, where the weight saving results directly in low fuel consumption in i.c. engines in particular.

"Even back at the manufacturing stage, the material saving means a lower demand for resources and therefore further CO2 savings."

JoinPlas said production of the couplings will begin in 2021. Continental and aft automotive have been developing synthetic connectors for cooling circuits, turbochargers and charge-air coolers since the end of 2016.