Blow-Molded Media Transport Assembly With Captive Functional Elements
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Solution Overview
Problem
Existing arrangements for the transport of media in electric vehicles and air conditioning systems are complex and costly to assemble, with a need for space-saving integration of functional elements and secure attachment to prevent loss during assembly.
Innovation Solution
The arrangement comprises a blow-molded base body with at least one functional element, where the functional element is positively fixed to the base body through shaping during the blow molding process, creating a captive connection and allowing for cost-effective high-volume production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If functional elements are integrated into the arrangement in a space-saving manner, then the assembly effort is reduced, but it must be ensured that the functional element is held on the arrangement in a loss-proof manner during assembly
Solution Approach 1:
The patent combines the base body and functional elements into a single integrated assembly produced by blow molding. The functional elements are molded directly onto the base body, creating a unified structure that eliminates separate attachment steps while ensuring secure, loss-proof connection through the molding process itself.
Solution Approach 2:
The functional elements are pre-positioned and secured to the base body during the blow molding process itself. The shaping of the base body during molding preliminarily creates the connection structure that permanently fixes the functional elements, eliminating the need for separate attachment operations and ensuring reliable fixation from the outset.
2Ease of manufacture
If the connection is formed by shaping the base body during blow molding, then the assembly can be produced cost-effectively in high volumes, but the functional element must be securely held during the molding process
Solution Approach 1:
The manufacturing process merges the base body formation and functional element attachment into a single blow molding operation. The functional elements are positioned within the mold cavity and remain there throughout the molding process, allowing both components to be produced and connected in one cost-effective high-volume manufacturing step.
Solution Approach 2:
The functional elements are pre-positioned in the mold cavity before the blow molding process begins. During molding, the base body material flows around and secures the functional elements, preliminarily establishing the connection structure that will permanently fix the elements to the base body after cooling.
3Ease of operation
If a positive fit is used to fix the functional element to the base body, then the assembly is easy to assemble, but the connection must prevent the functional element from becoming loose or lost
Solution Approach 1:
The positive fit connection is created by integrating the functional element directly into the base body through blow molding. The molding process forms interlocking geometric features that create a positive mechanical connection, ensuring the functional element is permanently captured within the base body structure without requiring separate fastening components.
Solution Approach 2:
The positive fit geometry is preliminarily formed during the blow molding process itself. As the base body material is shaped and cooled, it creates predetermined geometric interlocks with the functional element that permanently secure the element in place, eliminating the need for separate assembly steps to create the captive 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 solution enables easy assembly and transportation of the media transport arrangement while ensuring a secure, leak-proof connection between the base body and functional elements, reducing assembly effort and costs.
Implementation Method 1
the material of the base body can soften or melt under the influence of heat during blow molding and form a substance-to-substance bond with the functional element
Data Source
AI summary
An Arrangement for transporting media, comprising a base body formed as a blow-molded part and at least one functional element, wherein the functional element is positively fixed to the base body, wherein the positive fit is formed by shaping the base body during blow molding, and a method for producing an arrangement.