A Modular Coupling That Saves Material, Tools and Space

A connector is one of the smallest components in a vehicle’s thermal management system. Yet in electric vehicles, where batteries, power electronics and drive components must be maintained within precise temperature ranges, its influence on packaging, pressure loss, reliability and serviceability can be substantial.

In 2020, ContiTech MGW GmbH received the MATERIALICA Best of Award in the Process category for a modular plastic quick-coupling system developed by JoinPlas GmbH, the joint venture established by ContiTech and aft automotive.

In conventional connector families, every variant – and even every different orientation of the coupling head – may require a separate injection-moulding tool. This creates additional work in engineering, toolmaking and process validation.

The JoinPlas concept separates the coupling head from the connection spigot. Only one base head tool is required for each nominal size, combined with the appropriate tool for the respective spigot connection. The orientation of the coupling head can be adjusted during assembly and welding.

This flexibility is particularly important in confined installation spaces. The connector can be adapted to the available packaging while remaining accessible for unlocking during servicing. Cameras and other inspection systems monitor the production process automatically – from the sealing area and O-ring to welding quality, clamp position and final head orientation.

The benefits go beyond manufacturing flexibility. Reduced wall thickness lowers both component weight and plastic consumption by up to 15 percent. The geometry was also optimised for better flow: according to the submitted test data, the new design achieved lower pressure loss than the previous version even though the internal diameter was reduced from 16 to 15 millimetres.

High-performance plastics, optimised sealing solutions and a compact design make the coupling suitable for the demanding pressure and temperature conditions found in modern vehicle thermal-management systems.

Six years after receiving the award, the concept remains a strong example of why MATERIALICA evaluates materials, engineering, design and manufacturing processes together. Innovation does not always require a completely new component. Sometimes it begins by redesigning an established part so that it requires less material, fewer tools and less installation space – while performing better.

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Does your innovation combine intelligent material selection, advanced engineering, convincing design and measurable resource efficiency?

Submit it to the MATERIALICA Design + Technology Award 2026.

Application deadline: July 31, 2026

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