Vehicle AC Coupling Collar for Tolerance Compensation and Sealing
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Solution Overview
Problem
Existing coupling assemblies for air conditioning units in vehicles are complex to produce and inflexible, as they are often co-molded with specific materials, limiting their adaptability to different applications and conditions.
Innovation Solution
A coupling assembly where the tubular component and coupling component are manufactured separately, with the inner shoulder made of a less rigid elastomeric material co-molded on the coupling component, allowing for axial tolerance compensation and a seal to prevent fluid or gas leakage, enabling easy manufacturing and flexible application with different receiving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coupling component is made as one piece with the tubular component (co-molded), then the manufacturing is simplified, but the adaptability to different applications and conditions is reduced
Solution Approach 1:
The coupling assembly is divided into separate components: the tubular component and the coupling component. This segmentation allows each component to be manufactured independently using optimal materials and processes, then assembled together. The coupling component can be detached and replaced with different designs for different applications, while the tubular component remains reusable.
Solution Approach 2:
The tubular component is designed as a universal base that can work with multiple types of coupling components. By standardizing the interface and mounting area on the tubular component, the system achieves versatility across different applications while maintaining simple manufacturing of each individual component.
2Strength
If the coupling component is made from rigid material only, then the structural strength is improved, but the ability to compensate for mounting tolerances is reduced
Solution Approach 1:
The coupling component uses a composite structure combining rigid plastic material for the main body (providing strength) and elastomeric material for the inner shoulder (providing tolerance compensation). This composite approach allows both structural integrity and flexibility to accommodate mounting variations.
Solution Approach 2:
Different regions of the coupling component have different material properties: the outer structure uses rigid material for strength, while the inner shoulder uses elastomeric material specifically where flexibility and sealing are needed. This localized material differentiation optimizes both strength and tolerance compensation.
3Ease of manufacture
If the inner shoulder is made of rigid material, then the manufacturing process is simplified, but the sealing capability and tolerance compensation are reduced
Solution Approach 1:
The inner shoulder is manufactured using co-molding technology that combines plastic and elastomeric materials in a single process step. This approach maintains manufacturing simplicity while achieving superior sealing capability through the elastomeric material's ability to deform and conform to mating surfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies manufacturing, enhances flexibility, and provides a reliable seal for various conditions, allowing the same tubular component to be used with differently designed coupling components, improving adaptability and performance.
Implementation Method 1
the inner shoulder of the coupling component makes it possible to compensate for axial mounting tolerances
Implementation Method 2
forms a seal that prevents the passage of liquids into the gap between the coupling component and the tubular component
Implementation Method 3
A seal may be provided between the coupling component and the receiving part. This seal would prevent losses of fluid or gas
Data Source
Figure 1
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AI summary
Coupling assembly for an air conditioning unit of a vehicle, comprising a tubular component (2) and a coupling component (4) for coupling the tubular component (2) to a receiving part (6), wherein the coupling component (4) constitutes a separate component mounted on the tubular component (2), and wherein the coupling component (4) is securable to the receiving part (6) by means of a clamp (26) which engages in slots (24, 22) formed in the receiving part (6) and in the coupling component (4). The coupling component (4) consists of a collar which encircles the tubular component (2) and comprises a plurality of elastic tongues (11) that extend axially forward and radially inwards and are configured to engage in the tubular component (2) at a first shoulder (8a), and an inner shoulder (13) configured to abut axially against a second shoulder (8b) of the tubular component (2).