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ATE brake hose assemblies – Highest mechanical stability under load, highest compressive strength and resistance

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Hydraulically actuated brakes, and consequently brake hose assemblies, too, similar to today's designs, have been available from Alfred Teves (ATE) since the 1920s.

The first production car with a hydraulic brake from ATE was the 1927 ADLER Standard 6 and Favorit. This vehicle already featured brake hose assemblies on the front and rear axles.

The demands on the "connecting hose" in the Adler were similar to those raised today, aside from the temperature level and certain other things.

Owing to the growing demands, e.g., high temperatures, the testing of brake hose assemblies has acquired considerable scope.

ATE brake hose assemblies – History

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Brake hose assemblies are used at the transitions to parts which are subject to heavy dynamic stresses – steering knuckles or brake calipers, for instance. They ensure the proper transfer of brake fluid pressure to the brakes even under extreme conditions.

Along with mechanical durability and pressure resistance, chemical resistance, e.g., to oil, fuels and other environmental influences, as well as good thermal resistance are essential requirements.

To the high demands made on the system of brake lines, new ones have been added by ESP or TCS. The brake hose assembly plays an important role as damper and solves the problems raised by cramped installation positions.

Brake hose assemblies – Definition

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All weather factors

Flying stones

Road salt Temperature loads caused by drier or heat radiator temperatures > 100°C during refinishing of a vehicle

Operating pressure > 120 bar and briefpeak overpressure of 160 bar (max. about 10 min.)

Mechanical stresses caused, e.g., by improper laying of the brake hose

Damage like chafing

Other influences

Influences on brake hose assemblies

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If cracks are visible in the outer rubber layer of the brake hose, the car will fail to pass the next official inspection. In the initial stage (shortly after their formation) cracks have no negative influence on the operation of the brake hose, however.

But if the cracks in the outer rubber layer go undiscovered over a lengthy period, environmental influences (e.g., moisture, cleaning agents or lubricants) may damage the pressure-resisting braiding beneath the rubber layer, and that can substantially impair proper functioning.

The garage will have to examine the brake hoses carefully and replace them if necessary.

Cracks owing to excessive mechanical stress or

environmental influences

Effects of defective brake hose assemblies

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Present-day demands on efficient brake hoses

Use over a large temperature range must be possible

Low volumetric expansion of brake fluid

High flexibility in the cold

Negligible moisture absorption by inner and outer rubber layers

High chemical resistance to the additives in high-grade brake fluids

Great resistance to weathering and ozone

These demands too go to define the characteristics of our ATE brake hose assemblies.

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The brake hose assembly structure features an inner tube, double-layer braiding as pressure resistor, and an outer rubber layer to protect the pressure-resisting braiding from external influences.

Normally, at both ends of the hose threaded fittings are attached for making the connections with the brake pipe and caliper. But it is also possible to permanently connect the brake pipe with the brake hose assembly by means of a special connector (and to save effort for installation in the vehicle this way).

Outer rubber layer

Inner rubber layer

Double braiding

Design of ATE brake hose assemblies

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Braiding

Rayon

PVA = Polyvinyl alcohol

ATE brake hose assemblies - TypesMold-heated brake hose(vulcanized in a mold)TYPE 6/7

Freely heated brake hose(vulcanized in a water vapor atmosphere)TYPE 9

RAYON

RAYON

CR/EPDM

CR/EPDM

PVA

PVA

EPDM

EPDM

Rubber material

CR = Chloroprene Rubber

EPDM = Ethylene-propylene-diene

copolymer

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Improved properties of material and product

Outstanding resistance to dynamic loading -40°C to +120°C, briefly +160°C (max. about 10 min.)

Very good resistance to ozone

EPDM

PVAL

Minimal volumetric expansion under pressure and minimal water absorption

EPDM

PVAL

ATE brake hoses – Characteristics of Type 9

Service temperature range: -40°C to +120°C, briefly +160°C (max. about 10 min.)

Double braided layer of PVAL yarn

Improved EPDM

Vulcanized in a water vapor atmosphere

Very little elasticity under compressive stress, for well-modulated brake application

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Advantages & properties of ATE brake hose assemblies

Branded product – ATE utilizes the technology of OEM Continental.

Use of the most up-to-date technology – Mostly extruded connectors used, more than 70 braiding machines for producing the braid, autoclaves or vulcanizing presses and automatic surface control for the production of the inner and outer rubber layers

Quality & safety guaranteed – Test stands and laboratories are amply available for testing to customer specifications.

Extraordinary quality standard owing to certification – ATE brake hose assemblies comply with FMVSS106, and production is certified to ISO 14001. In addition, with the in-house ATE N standard they exceed the legal requirements.

Hose marking – The DOT symbol (DOT = US Department of Transportation) confirms the agreement of the hose with the most common motor vehicle safety regulations.

High level of quality – Continental uses only high-grade, long-lived materials to manufacture the brake hose assemblies. The surface protection of the connectors of the ATE brake hose assemblies is free of Cr-6, complying with the EU end-of-life-vehicle directive.

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ATE brake hose assemblies – Fittings / extras

To the high demands made on the system of brake lines, new ones have been added by ESP or TCS. The brake hose assembly plays an important role as damper and solves the problems raised by cramped installation positions.

To simplify fitting, preassembled brake hose assemblies are used to reduce the number of unchecked screwing operations and enabled simplified fastening in the vehicle.

ATE brake hose assemblies are available in OE quality together with fittings of, e.g., the following types:

Internal thread

External thread

Spacer

Protective spring

Floating attachment by means of clip-in rubber fasteners

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ATE brake hose assemblies – Notes on installation

Fit brake hose assemblies in exact sizes and do not twist.

Do not bend too short to fit. It's better to use an additional banjo union with banjo bolt.

Lay brake hose assemblies so that chafing is impossible.

Where there is danger of contact, make the brake hose assembly safe with a protective hose or by means of an additional hose clamp and tension spring.

Should a brake hose assembly additionally be provided with a protective hose, this hose must neither be displaced nor removed.

Do not lay near the exhaust system. Brake hose assemblies also must not come near the exhaust system when the vehicle springs deflect or the wheels are turned. If necessary, fit additional heat insulation.

Do not lay in the immediate vicinity of lubrication points so as to avoid contact with excess oil or grease.

Further details are contained in the instructions for use included with every ATE brake hose assembly!