Composite Coupling Pilot Structure for Refrigerant Leak Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Refrigerant-based cooling systems in vehicles face issues with damage, leakage, and high emissions due to heat, pressure, and vibration, which existing seal structures and connection arrangements fail to adequately address, particularly in mobile air conditioning systems where lightweight and durable connections are required.
Innovation Solution
A coupling system featuring a ring-shaped insert with a metal ring encased in plastic, combined with pillar devices to mitigate compressive forces and prevent leakage, using a composite material that resists creep and deformation, and incorporating a collar for secure sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional seal structures and connection arrangements are used in refrigerant cooling systems, then the system can be assembled and operated, but the connections are susceptible to damage and leakage due to heat, pressure, and vibration
Solution Approach 1:
The pilot component is constructed as a composite structure with a metal core providing structural strength and creep resistance, surrounded by a plastic material that provides sealing compatibility and thermal insulation. This composite construction enables the pilot to maintain dimensional stability under thermal and pressure loads while preventing refrigerant leakage.
Solution Approach 2:
The connection system is divided into distinct functional components: the composite pilot for structural stability, the seal washer for leakage prevention, and the collar for mechanical support. This segmentation allows each component to be optimized for its specific function, with the pilot specifically designed to resist compressive forces and maintain sealing pressure.
2Weight of moving object
If lightweight materials are used for couplings in mobile air conditioning systems, then the system weight is reduced, but the connections become more susceptible to creep and deformation under compressive forces
Solution Approach 1:
The pilot uses a metal-plastic composite construction where the metal core provides high compressive strength and creep resistance, while the plastic outer layer maintains the overall lightweight characteristic. This allows the coupling to be significantly lighter than solid metal alternatives while maintaining sufficient structural stability under operating conditions.
Solution Approach 2:
The metal material is strategically positioned in the core region where compressive forces are highest, providing localized strength where needed. The plastic material occupies the outer regions where lower strength is acceptable, optimizing the weight-strength balance by placing materials according to their functional requirements at different locations.
3Ease of manufacture
If existing connection arrangements are used, then the system can be manufactured and assembled, but they fail to maintain consistent sealing pressure under varying thermal environments
Solution Approach 1:
The composite pilot is designed with specific thermal expansion characteristics that compensate for thermal variations in the sealing interface. The different thermal expansion coefficients of the metal and plastic materials work together to maintain relatively constant sealing pressure across a range of operating temperatures, ensuring consistent sealing performance.
Solution Approach 2:
The composite structure of the pilot automatically compensates for thermal effects without requiring external adjustment mechanisms. The inherent properties of the metal-plastic composite provide self-regulating sealing pressure maintenance as temperature changes, eliminating the need for complex thermal compensation devices.
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 system effectively reduces refrigerant leakage and emissions by maintaining consistent compressive forces across varying thermal environments, enhancing the durability and reliability of connections in mobile air conditioning systems.
Implementation Method 1
a ring shaped insert (102, 502) having a metal ring encased a plastic material to include a composite material
Implementation Method 2
a collar (112) to secure the sealing element (110) to the coupler (118)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A coupling system (100) is disclosed. The system (100) includes an insert (102), an upper part (106) and a flange (104). The insert (102) includes a plurality of pillar devices and has a ring comprised of plastic material. The upper part has a circular shaped opening. The flange has a washer or elastomer seal element (110). Pilot (114 and 116) are a molded plastic that encase the insert ring (102). The washer element is adjacent to and concentric with the circular shaped opening and is comprised of a rubber material. The pillar devices are configured to mitigate force from the upper part to the washer element of the flange. The insert or ring (102) can have an L-shaped profile (502).