Mold concept for serial production taking into account the best injection point location and placing the parting lines correctly for best ventilation results

Best compromise between manufacturability and market competitiveness.

Batteries must be protected from the effects of hazardous sources (thermal runaway). High-voltage batteries consist of interlinked lithium cells, are available from 12V to > 800V and today have an energy density of over 200 Wh/kg. Pressure compensation and emergency degassing elements are required for optimal protection.

We call it the Berstring®. The innovative Berstring® safety valve combines all the features necessary for comprehensive protection. The functional principle has been tried and tested many times and can be adapted to individual conditions.
Berstring® safety valves are offered for battery housings of different sizes and can exchange more than 500 l/h of air at a differential pressure of 70 mbar. In case of thermal runaway our Berstrings® open with a short notice <50µs. The air volume and the bursting pressure are up to your request.

Due to engine downsizing, more and more energy is released in the form of vibrations at the crankshaft. A system is required which can absorb these huge vibrations and torsional oscillations. 

Friction bearings made of tribologically-optimized polyamides from KKI for viscous torsional vibration dampers fulfill the requirements. Viscous torsional vibration damper systems can effectively minimize vibrations and torsional oscillation in low-consumption and emission-reduced engines for the automotive industry. Such systems are fully production-ready.

Viscous torsional vibration damper systems minimize vibrations and torsional oscillations. Effective, low-consumption and emission-reduced engines for the automotive industry are fully production-ready.

Simultaneously acting radial and axial loads usually require the combination of two bearing types. This means increased installation space, since each bearing must be designed according to the requirements.

Here too, it took a bright mind to come up with the solution. A clever engineer devised a combined axial-radial bearing that is essentially an entirely new machine element. The combination of radial and axial bearing in a single component significantly reduces space requirements. Forces in both radial and axial direction are absorbed by the build-up of a lubricating film between the bearing halves. The effect is reinforced due to the tilting of the bearing, thus enabling extremely high bearing forces. The assembly is almost identical to the installation of a deep groove ball bearing. Minimum lubrication by any medium (except air) is required.

The development of a new bearing element for the different requirements such as high speeds, extreme robustness and smooth running. A bearing type that is frequently used in the new E- mobility applications.

The solution is our new machine element called "Hydrodynamic 3D-Plain Bearing". The new "Hydrodynamic 3D-Plain Bearing" withstands bearing loads that are absorbed by axial needle bearings, thrust washers or plain bearings.

• Reduction of NVH (Noise Vibration Harshness) in torque transmission

Replacement of a metal gear rim by a polymer component

The individual rotating elements in the drive train must be mounted against each other or against the case. A needle bearing or bronze bearing is often used for this purpose. These require a complex installation or a large axial installation space.

KKI's thrust washers replace typical axial bearing elements, e.g. needle bearings, and are already available in series. Thanks to the polymer solutions, the axial installation space can be reduced or used for other components. Through special material-surface combinations, both friction moments and heat input can be reduced. If required, the bearing can be secured against twisting and/or equipped with snap-in lugs for overhead mounting. By using TriboKon, the weight can be reduced considerably. Minimum lubrication through a medium is recommended.

In addition to traditional rectangular sealing rings, which seal on the outer surface, there are some applications where the seal is applied to the inner diameter. These rectangular sealing rings (REDI) are used when a groove cannot be inserted into the shaft due to cross-bores in the shaft or the cross-sections are too small.

Due to the special material surface combination and KKI's tried-and-tested REDI design, both leakage and frictional torque can be significantly reduced compared to conventional solutions from iron castings. An expansion by centrifugal forces is effectively prevented by special geometries and materials.

Due to the numerous rotating components in the drive train, they have to be separated from one another, not only to reduce frictional torque but also to prevent the wear of two elements.

The KKI axial discs reliably separate two rotating elements. These discs are installed as a flying disc, since in these applications no space is available for anti-rotation devices. In order to reduce the resulting frictional torques, the disks are equipped with a special material-surface combination. This technology also delivers higher durability under extreme stress conditions compared to bronze discs, for example. The use of TriboKon can be used to cover different wall thicknesses and applications. Through the use of polymeric materials and reduced wall thicknesses, considerable weight reduction and space savings can be achieved.

Applications with difficult assembly procedures (e.g. blind mounting in large gears) require a consistent mounting diameter. Otherwise, damage to the rectangular sealing ring (REDI) cannot be excluded, leading to costly replacements. Typically, cast iron sealing rings are used here, which lead to material-specific disadvantages during assembly and use.

With the HOOK method developed by KKI, the REDI is assembled as usual and hooks itself to a defined diameter. This technology can be implemented in almost all materials, dimensions and variants. In contrast to cast iron rings, mounting is carried out within the groove. The REDI therefore lies cleanly inside the groove during the assembly of surrounding components, ensuring easy, error-free installation. What's more, a reduced lead-in chamfer is required as the HOOK technology almost completely compensates the expansion.

Three trends currently determine the rectangular sealing ring (REDI) market. Firstly, stricter exhaust gas regulations demand a noticeable reduction in frictional torque and leakage losses in commercially available REDI materials. Secondly, the technologies required for this purpose should only have minimal effects, or the material selection should generally be customized to the application. Thirdly, due to increasingly complex transmissions, error-free assembly is crucial.

With the EVO-REDI, KKI has proved that these challenges can be met. The EVO-REDI reduces friction and leakage to a minimum. The leakage can therefore be used where it is most effective. What's more, the special design of EVO-REDI facilitates error-free assembly. These modifications do not affect the available installation space, which is why the customer does not need to adapt the surrounding components, and existing sealing rings can be replaced 1:1. Through the use of TriboKon polymers further commercial potential savings can be achieved.

The development of a new bearing element for the different requirements such as high speeds, extreme robustness and smooth running. A bearing type that is frequently used in the new E- mobility applications.

The solution is our new machine element called "Hydrodynamic 3D-Plain Bearing". The new "Hydrodynamic 3D-Plain Bearing" withstands bearing loads that are absorbed by axial needle bearings, thrust washers or plain bearings.

Manufacture of a large thrust washer that can easily be exchanged in workshops as a repair solution

Instead of a complex thrust washer, several small thrust segments are implemented and inserted.

The level of a truck trailer is to be controlled by air springs, for example when the trailer is unevenly loaded or takes a curve. The system is designed to compensate for the "misalignment".

KKI pneumatic valve bodies made of plastic replace the currently used aluminum valve bodies. The valve bodies regulate actively and dynamically the air supply of the air springs. The trailer height is constantly monitored and maintained at the desired position and level.
No mechanical rework is needed on the valve body.

For parking and maneuvering a truck trailer, a system is required which opens, closes and controls the compressed-air brakes.

KKI pneumatic valve bodies made of plastic replace the currently used aluminum valve bodies. The valve bodies control the air supply to the compressed-air brakes.
The trailer can be parked and maneuvered with the highest degree of safety and precision.
No mechanical rework is required on the valve bodies.

A bracket with corresponding locking contour is inserted into the transmission to prevent the axial movement of non-activated shift forks. This comes into play when the shift fork lock fails. For this purpose, a sheet metal bending component is used, which is very costly to manufacture and requires several processing steps.

The KKI locking bracket replaces the previously used sheet metal bending component. To manufacture the component by injection molding, the existing component was re-engineered to adopt a design compatible with injection molding. This polymer solution not only reduces the weight but also enables single-process production. The sheet metal bending part, in contrast, had to be produced in several steps.

In addition, the polymer solution has the advantage that the component can be used in several transmission types through appropriate optimization.

Manufacture of a large thrust washer that can easily be exchanged in workshops as a repair solution

Instead of a complex thrust washer, several small thrust segments are implemented and inserted.

• Reduction of NVH (Noise Vibration Harshness) in torque transmission

Replacement of a metal gear rim by a polymer component

Mold concept for serial production taking into account the best injection point location and placing the parting lines correctly for best ventilation results

Best compromise between manufacturability and market competitiveness.