Climate Port Assembly With Spacer Bonding for Leak-Free Joints
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Solution Overview
Problem
Existing port adapter assemblies in climate conditioning systems are prone to refrigerant leaks due to improper installation or brazing, leading to reduced system performance, potential environmental harm, and system inefficiencies.
Innovation Solution
A port assembly group comprising a cup-shaped adapter part and a spacer, where the spacer has a partial cylindrical bonding surface that complements the fluid line's outer surface, providing a strong and reliable connection through gluing, which is more robust than traditional brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to connect the adapter to the fluid line, then a strong joint can be obtained, but refrigerant leaks may occur due to improper installation or brazing
Solution Approach 1:
The patent replaces the thermal brazing process with a mechanical expansion system. The adapter is inserted into the fluid line and expanded mechanically to create a tight seal, eliminating the need for brazing operations and associated leakage risks while maintaining joint strength.
Solution Approach 2:
The patent introduces an expansion mechanism as an intermediary between the adapter and fluid line. This expansion system acts as a mediator that creates a reliable seal through controlled mechanical deformation, ensuring leak-free operation without requiring precise brazing skills.
2Strength
If brazing is used to connect the adapter, then a strong joint can be obtained, but the installation process becomes complex and requires specialized skills
Solution Approach 1:
The patent substitutes the complex thermal brazing process with a simple mechanical insertion and expansion system. The adapter is inserted into the fluid line and expanded using basic tools, making the installation process straightforward and eliminating the need for specialized brazing equipment and skills.
Solution Approach 2:
The expansion mechanism is designed to be self-contained within the adapter assembly. The expansion elements are pre-loaded and automatically engage with the fluid line upon insertion, allowing the system to complete the sealing action without requiring complex external equipment or specialized operator skills.
3Strength
If brazing is used to fix the adapter, then a strong connection can be obtained, but refrigerant leaks and contamination can still occur
Solution Approach 1:
The patent replaces the brazing process with a mechanical expansion sealing system that creates a uniform, controlled seal between the adapter and fluid line. This eliminates the heat-affected zones and potential defects associated with brazing, preventing refrigerant leaks and contamination while maintaining strong connection strength.
Solution Approach 2:
The patent changes the sealing mechanism from thermal (brazing) to mechanical (expansion). By controlling the expansion parameters of the adapter, a consistent and reliable seal is achieved that prevents refrigerant leakage and contamination, overcoming the limitations of brazing where improper installation can lead to leaks.
4Ease of manufacture
If traditional port adapters are used, then the connection can be made, but the bonding surface area is limited by the hole magnitude
Solution Approach 1:
The patent transitions the bonding interface from a two-dimensional annular surface (limited by hole circumference) to a three-dimensional expanded surface. The expansion mechanism creates radial and axial contact areas, dramatically increasing the bonding surface area while maintaining connection feasibility through the same insertion process.
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
The improved connection provides a stronger joint with larger bonding surfaces, reducing the risk of refrigerant leaks and enhancing the reliability and durability of the port assembly, while also being cost-effective and adaptable to various fluid line diameters and materials.
Implementation Method 1
The spacer (10) is glued via the first bonding surface (12) to the adapter part (2)... The second bonding surface (16) is provided for being bonded to the outer surface (24) of the fluid line (20)
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
Port assembly group for being attached to a fluid line of a climate conditioning system, comprising a basically cup-shaped adapter part having a bottom portion with a central opening and an outer surface. A spacer having a first bonding surface on a first side of the spacer is formed complementary to the outer surface of the bottom portion to which the first bonding surface faces. A first central tube section protrudes perpendicular from the first bonding surface and is configured for being received by the central opening in the bottom portion. A second bonding surface is located on a second side opposite to the first side and is formed as a concave partial cylindrical surface. A second central tube section is aligned by a central tube section axis with the first central tube section and protrudes from the partial cylindrical surface.