Continental has introduced the world’s first product it says can lead to commercial vehicle weight savings of up to 12 kilograms per axle. Produced by the company’s ContiTech Air Spring Systems business unit, the air spring contains a plastic piston that saves up to 75% of the weight of conventional steel pistons. 
Another breakthrough feature is that the air spring has an interior volume that can be used entirely for enhancing comfort. This new product has debuted on the Mercedes-Benz Actros, a vehicle that Continental says utilizes a completely revised drive and chassis concept in which the ContiTech air springs with plastic pistons play a “decisive” role.
According to Continental, the breakthrough in the spring’s development came around five years ago when improved material technology was able to be paired with a completely simulation method.
“We had to spend a long time looking around in the market before finding a raw material manufacturer with the relevant know-how for the material and the necessary analysis skills,” states Diethelm Bauch, the segment manager in charge at ContiTech, talking about the development process. “We carried the idea around with us for a long time.”
Bauch adds that, once a breakthrough was reached, ContiTech worked closely alongside Mercedes-Benz to develop a working product: “Thanks to the close, partnership-based cooperation with the customer’s chassis developers, development of this product proceeded very quickly.”
Air spring systems with plastic pistons have been used for a number of years now, particularly in trailers. However, these conventional systems only use the bellows volume for riding comfort. The associated pistons are generally completely closed.
“Not until we had found the right raw material, the necessary analysis skills and an intelligent product design could we achieve the strength which allows us to produce an open plastic system with a useful piston volume for the first time,” Bauch explains. “This revolution gives the Actros, together with the sleeve-type air springs produced by us for supporting the driver’s cab, much greater riding comfort and also gives our company a clear edge over the competition.”
ContiTech believes the potential the system holds for commercial vehicle developers becomes particularly apparent when the weight is low. “Chassis developers are very interested in obtaining this advantage for themselves,” Bauch stresses. In addition to potential fuel savings, the weight reduction also opens up space for installing further components without increasing overall weight or reducing the useful load. Also, the use of plastic reduces dependency on the price of steel – which Conti says creates a clear price advantage.
At present, ContiTech Air Spring Systems operates seven locations on three continents, and has plans in place to increase its global production network. “In order to further strengthen our international market position, we are planning to set up production locations in India and Brazil next year,” Bauch reports. “This will allow us to continue exploiting opportunities in the future and achieve clear growth in the markets of the future as well.” (Tyres & Accessories)
