Hydraulic Accumulator Weld Joint for Lower-Corrosion Assembly

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Solution Overview

Problem

Existing hydraulic accumulator designs require complex and costly manufacturing processes for creating high-strength welded connections between fluid connection points and accumulator housings, often involving fillet welds that are prone to corrosion and increase production costs.

Innovation Solution

A hydraulic accumulator design that eliminates the need for fillet welds by using a flat, inclined annular cone recess in the connecting body, allowing for direct weld seams between the connecting body and the accumulator housing, which are created using laser or electron beam welding, reducing manufacturing complexity and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fillet welds are used to join connecting bodies to accumulator housing, then connection strength is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Instead of creating a fillet weld that projects outward from the joint, the patent inverts the approach by creating a recess that receives the weld material, allowing the weld to be embedded within the joint interface rather than protruding outward. This inversion simplifies the manufacturing process while maintaining connection strength.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces a recess as an intermediary structural feature that facilitates the welding process. This recess acts as a mold or cavity that guides the weld material and ensures proper weld geometry, thereby simplifying the manufacturing process while maintaining high connection strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If fillet welds are used to join connecting bodies to accumulator housing, then connection strength is improved, but risk of corrosion increases

Engineering Contradiction:

Improveconnection strengthVSAvoidcorrosion risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potential harm of exposed weld material to corrosive environments into a benefit by designing a recess that embeds the weld material, thereby protecting it from corrosion while maintaining the strength benefits of the weld.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If complex welding processes are used for connecting bodies, then connection reliability is improved, but production cost increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The recess is pre-formed in the connecting body or housing before the welding process. This preliminary action prepares the joint interface in advance, ensuring that the subsequent welding process is simplified and can be performed more efficiently, thereby reducing production costs while maintaining connection reliability.

Inventive Principle:

Principle #10Preliminary action

4Object-affected harmful factors

If smooth internal weld seams are created from inside the housing, then protection from environmental corrosion is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveprotection from corrosionVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Instead of attempting to create a smooth internal weld seam from inside the housing (which would require complex internal welding operations), the patent inverts the approach by creating a recess that receives the weld material from the outside, thereby achieving both corrosion protection and manufacturing simplicity.

Inventive Principle:

Principle #13The other way round (Inversion)

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 approach results in a more robust and cost-effective connection method with reduced risk of corrosion, enabling efficient mass production of hydraulic accumulators with simplified manufacturing processes.

Implementation Method 1

permanently join the connecting body to the accumulator housing using a fusion welding process

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

created using laser or electron beam welding

Methodology Applied

Scientific EffectLaser beam welding: Laser Beam Welding

Implementation Method 3

created using laser or electron beam welding

Methodology Applied

Scientific EffectElectron beam welding: Electron Beam

Data Source

PatentEP4229302B1Hydraulic accumulator

Publication Date: 2025.06.25 HYDAC TECH GMBH

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AI summary

The invention relates to a hydraulic accumulator, in particular a diaphragm accumulator, comprising an accumulator housing (10) and a separating element (12) which is arranged therein and separates two media chambers (14, 16) from each other. The accumulator housing (10) has at least one fluid connection point (24, 26) which opens into an adjacent media chamber (14, 16) and has a connection body (28, 82) with a fluid passage point (80, 98) that is connected to the accumulator housing (10) via a welding seam (40). The invention is characterized in that the connection body (28, 82) has an annular outer circumferential surface (72, 96) on the connection region facing the accumulator housing (10), and when the end face of the connection body is placed on the accumulator housing (10), the connection body (28, 82) forms a transition point (120), along which the welding seam (40) runs.