Deformable Coupling Element for Stable Actuator-Valve Assembly
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Solution Overview
Problem
Existing coupling elements for actuator and valve connections in radiator systems face challenges with stability and manufacturing complexity, particularly with plastic snapping hook elements that can break under excessive tightening and Siemens' solution with a wire between the nut and actuator neck being difficult to manufacture and assemble automatically.
Innovation Solution
A coupling element with a deformable portion that irreversibly bends to form a projection engaging with an annular groove on the actuator, creating a non-detachable but rotatable connection, allowing for a simplified and stable mechanical connection between the actuator and valve using a compression tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plastic snapping hook elements are used to connect the nut to the actuator, then the assembling procedure becomes easy, but the connection can break if the nut is tightened too hard
Solution Approach 1:
The patent changes the physical state of the coupling element from a rigid plastic hook to a deformable material that undergoes permanent deformation during tightening. The deformable portion is designed to yield and form a projection that engages with the actuator groove, transforming the connection mechanism from a snap-fit to a deformation-based mechanical lock that maintains reliability under tightening forces.
2Reliability
If a wire is used to connect the nut to the actuator neck, then the connection becomes mechanically stable, but the manufacturing process becomes complicated and automatic assembly becomes difficult
Solution Approach 1:
The patent merges the coupling element and the connection feature into a single integrated component. The deformable portion is formed as an integral part of the coupling element body, eliminating the need for separate wires or additional assembly steps. The deformable portion is shaped to automatically form the engagement projection when compressed, combining the coupling and connection functions in one element.
Solution Approach 2:
The coupling element performs its own connection function through the deformable portion that automatically forms the engagement projection during the tightening process. The deformation occurs as a natural result of applying compression force during normal assembly, eliminating the need for separate wire installation or complex manufacturing processes.
3Ease of manufacture
If the coupling element uses a deformable portion that irreversibly bends to form a projection, then the production process is simplified and manufacturing yield improves, but the connection must be non-detachable
Solution Approach 1:
The patent introduces dynamic behavior to the coupling element through the deformable portion that changes shape during assembly. The material transitions from an undeformed state to a permanently deformed state with an engaged projection, allowing the connection to be formed through controlled deformation during tightening while maintaining simplicity in the manufacturing 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
This solution provides a stable, non-detachable, and rotatable connection between the actuator and valve, simplifying the production process, improving manufacturing yield, and reducing costs by enabling precise spatial adjustment and reliable mechanical contact.
Implementation Method 1
a deformable portion (130), which is shaped in such a manner, that, as a result of a compression along an axial direction of the coupling element, the deformable portion irreversibly bends such that a projection (130a) is formed
Data Source
AI summary
A coupling element has a first interface, which is adapted to mechanically connect the coupling element to an actuator, a second interface, which is adapted to mechanically connect the coupling element to a valve, and a deformable portion, which is shaped in such a manner, that, as a result of a compression along an axial direction of the coupling element, the deformable portion irreversibly bends such that a projection is formed. Thereby, the projection is adapted to permanently engage with an annular groove formed at the actuator, such that the coupling element and the actuator are connected with each other in a non-detachable but rotatable manner.