Blow-Molded Plastic Duct Shrink Fitting for Engine Intake
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Solution Overview
Problem
Existing pipe systems for internal combustion engine intake systems, particularly those using blow-molded plastic ducts, face challenges in achieving a reliable and tight connection between duct parts without the need for external tools or processes like welding.
Innovation Solution
The solution involves inserting a fitting into a blow-molded duct part while the plastic is still plasticized, allowing it to shrink and adhere, creating a nonpositive connection by adherence, which can be enhanced with material engagement through fusion or positive locking mechanisms, eliminating the need for additional tools like welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect duct parts, then connection reliability is improved, but device complexity and manufacturing cost increase due to requiring external welding tools and processes
Solution Approach 1:
The connection process is merged with the blow molding process itself. The fitting is inserted into the duct part while the plastic material is still plasticized (in molten state), and the connection is formed as an integrated part of the molding cycle, eliminating the need for separate welding operations and external tools.
Solution Approach 2:
The fitting is inserted into the duct part before the plastic material fully solidifies. By performing the insertion action while the material is still plasticized, the fitting becomes embedded in the material during cooling, creating a permanent connection without requiring subsequent welding or assembly operations.
2Reliability
If welding is used to connect duct parts, then connection tightness is improved, but manufacturing time increases due to external ejection and welding processes
Solution Approach 1:
The connection operation is combined with the blow molding process into a single integrated operation. The fitting insertion and connection formation occur during the molding cycle itself, eliminating the sequential steps of ejection, positioning, and welding that would otherwise be required, thereby significantly reducing total manufacturing time.
3Ease of manufacture
If a nonpositive connection by adherence is used, then ease of manufacture is improved, but connection strength may be insufficient without additional locking mechanisms
Solution Approach 1:
The physical state of the plastic material is changed during the connection process. The material is maintained in a plasticized (molten) state during fitting insertion, then cooled to solidify and create a strong permanent connection. This parameter change allows the material to transition from a fluid-like state that accepts the fitting easily to a solid state that provides strong mechanical strength.
Solution Approach 2:
The connection structure becomes a composite of the plastic material and the fitting material. The plastic material encapsulates the fitting, creating a composite structure where the two different materials work together to provide both ease of insertion and strong mechanical strength, combining the properties of both materials in the final connection.
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 method enables a reliable, tight, and efficient connection directly within the mold, optimizing the pipe system's stability and reducing the need for external tools, applicable to various fluid systems including turbochargers and air intake systems.
Implementation Method 1
During the cooling the at least one blow-molded duct part shrinks on the at least one fitting. So a tight connection can be realized.
Implementation Method 2
the plastic material for realizing the at least one blow-molded duct part is plasticized by heating and formed in a blowing mold
Data Source
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AI summary
The present invention relates to a pipe system for a fluid, in particular a gas, in particular of an intake system (10) or a turbocharger of an internal combustion engine, in particular of a motor vehicle. Further the present invention relates to a method and an apparatus for connecting at least one duct part (12) of a pipe system (10). The pipe system (10) has at least one blow-molded duct part (12) made of plastic and at least one fitting (18) for connecting the at least one blow-molded duct part (12) with another part (20) of the pipe system (10). The fitting (18) is inserted tight in the at least one blow-molded duct part (12). The at least one blow-molded duct part (12) is shrinked on the at least one fitting (18).