Annular Connector Captive Sealing Washer Design
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Solution Overview
Problem
Existing ring connector couplings for fluid lines require handling multiple components during assembly, leading to potential errors and existing anti-loss solutions are either expensive or require high forces for deformation.
Innovation Solution
A conical sealing washer with a cylindrical bore is used, which deforms into a flat shape upon assembly, creating a conical bore that engages an annular groove on the banjo bolt, ensuring secure capture without high forces or complex production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thorus-shaped sealing ring with conical area is used to engage in annular groove, then the sealing ring cannot be unintentionally removed (anti-loss function), but the production cost increases due to multiple forming operations
Solution Approach 1:
The sealing ring is divided into two functional parts: a simple flat sealing disk and a separate conical anti-loss element. The conical element is inserted through the cylindrical bore of the flat seal, combining the sealing function with the anti-loss function. This segmentation allows each part to be manufactured simply and independently, then assembled together, avoiding the need for complex multi-step forming operations on a single component.
Solution Approach 2:
The conical anti-loss element is nested within the cylindrical bore of the flat sealing disk. This nesting arrangement allows the conical element to be held captive by the flat seal during assembly and installation, while still performing its anti-loss function by engaging with the annular groove. The nested structure enables both functions to work together without requiring complex integrated geometry.
2Reliability
If axial compression is used to plastically deform the sealing disk for captiveness, then the sealing disk can be secured, but high surface pressure is required that limits material choices for the ring socket
Solution Approach 1:
Instead of using axial compression to deform the sealing disk (as in prior art), the invention inverts the approach by using bending forces applied radially through the conical element. The conical geometry converts radial insertion forces into bending moments that plasticize the sealing disk material, securing it without requiring high axial compression forces on the ring socket.
Solution Approach 2:
The invention changes the deformation parameter from axial compression to radial bending. By inserting the conical element through the cylindrical bore, bending forces are applied to the sealing disk, causing plastic deformation that secures the element. This parameter change reduces the force requirements and eliminates material selection constraints for the ring socket.
3Ease of operation
If four separate components are handled during assembly, then the coupling can be assembled, but errors due to omission of components can easily occur
Solution Approach 1:
The flat sealing disk and the conical anti-loss element are merged into a single integrated component. The conical element is inserted through the cylindrical bore of the flat seal, creating a unified part that performs both sealing and anti-loss functions. This merging reduces the number of separate components to be handled during assembly from four to three, and simplifies the assembly process while preventing component omission errors.
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 allows for secure assembly of components with simple and inexpensive production, using lower forces than traditional methods, eliminating the need for axial compression and maintaining the sealing integrity.
Implementation Method 1
the sealing disk has a flat shape after it has been put on by plastic deformation
Implementation Method 2
the bore forms an annular edge on the side of the sealing disk pointing towards the ring socket, the diameter of which is smaller than the outside diameter of the banjo bolt and the annular edge of the bore engages the annular groove of the banjo bolt
Data Source
Figure 1~2
AI summary
Fig. 1 illustrates an annular coupling (1) according to the invention, with a hollow screw (2), with an annular connector (3), a flat ring seal (4) and a sealing washer (5). The flat ring seal (4) which is arranged between the head (6) of the hollow screw (2) and the annular connector (3) seals the head (6) in relation to the annular connector (3). The hollow screw (2) has an annular groove (8) at the end thereof which projects out of the annular connector (3). The sealing washer (5) is of conical design and has a cylindrical bore (9). In said state, the sealing washer (5) can be pushed onto and pulled off again from the hollow screw (2). Fig. 2 shows the same arrangement of hollow screw (2), annular connector (3) and seals (4) and (5), but here the sealing washer (5) has been deformed back into a flat shape. By means of said deformation back, the previously cylindrical bore (9) is now of conical design and, on the side facing the annular connector (3), an annular edge (10) is formed, the diameter of which edge is smaller than the diameter of the hollow screw (2). The annular edge (10) engages in the annular groove (8) such that the sealing washer (5) can no longer be pulled off from the hollow screw (2). The components of the annular coupling (1) are therefore connected captively to each other.