ContiTech Develops Flexible High-Tech Hoses for Turbochargers

For high pressures and temperatures: well-thought out solutions for all tasks involving carrying of media

The hybrid hose is manufactured combining processes and materials from extruded and knitted hose production with those from wrapped hose production
(PresseBox) ( Hannover, )
The automotive industry is facing major challenges: vehicles need to be produced at lower cost, be more eco-friendly, efficient and comfortable and perform better with smaller engines. With its hoses and hose line systems for the turbocharger, ContiTech AG, as the world's largest rubber and plastics technology specialist, is making a considerable contribution to realizing future-compatible vehicle generations.

Hybrid technology

For the upcoming generations of highly-supercharged engines, adaptable, temperature-resistant hoses capable of withstanding a positive pressure of over 3 bar - and different media flowing through them - will be needed. For this reason ContiTech Fluid Technology has developed a flexible hybrid hose that combines the advantages of an extruded and knitted hose with those of a wrapped hose and for the first time satisfies all these requirements in equal measure. "Different combinations of knitted and rubber materials can be combined to accommodate different temperatures," says developer Robert Dill explaining their impressive versatility. Curved charge air hoses made with suitable hybrid technology developed for other applications enable a positive pressure of over 3.5 bar.

High-performance charge-air hose

In cooperation with its partners in the automotive industry, ContiTech brings tailor-made solutions quickly to production readiness: New high-tech knitted hoses went into volume production for the Mercedes-Benz E Class. The charge-air hoses are designed for pressures of up to 3.2 bar - without compromising the complex contour in the slightest. For one special application, the hose has even been tested at a positive pressure of 4 bar.

Cost-saving, eco- and climate-friendly cars make major demands on mate-rials and technology. With new materials and processes, ContiTech is establishing the prerequisites for performance-oriented, ecological mobility. In doing so, developers draw on experiences made in other corporate divi-sions. ContiTech Fluid Technology is therefore able to offer optimally matched components for all tasks involving the carrying of media in the turbocharger as well as charge-air, cooling and lubrication systems.

Material competence for turbocharger lubrication and cooling

ContiTech is developing corrugated stainless steel pipes for turbocharger lubrication that are suitable for the high temperatures that prevail in the application. Stiff corrugated stainless steel pipes can be installed more easily. The fact that they are corrugated makes them flexible enough to absorb movements and vibrations. In addition, they demonstrate high corrosion and temperature resistance.

For turbocharger cooling, lines were developed in which two aluminum pipes are joined with a hose section without the need for soldering, thus making the process cost-efficient. The lines can be manufactured in highly automated production, making them competitive with products from low-wage locations.
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