Elastomer Outlet Main Tube Assembly With Fewer Welded Joints
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Solution Overview
Problem
The existing manufacturing process for temperature control lines in drive batteries involves high costs due to the need for multiple welding operations and separate components, particularly for connecting corrugated tube segments to heat exchangers, which complicates installation and maintenance.
Innovation Solution
A main line system with a main tube and elastomer outlets, allowing for a single injection-molded part that can be welded directly to the main tube, eliminating the need for corrugated tube segments and reducing the number of welding operations to one per outlet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If corrugated tube segments are used to connect outlets to the main tube, then flexibility and tolerance requirements are improved, but the number of welding operations and manufacturing complexity increase
Solution Approach 1:
The patent combines the outlet and corrugated tube segment into a single integrated component. The outlet now includes an integrated corrugated section that provides flexibility without requiring separate corrugated tube segments, reducing the total number of parts while maintaining installation flexibility.
Solution Approach 2:
The outlet is designed to serve multiple functions: it provides fluid connection, flexibility through the integrated corrugated section, and structural support. This multi-functional design eliminates the need for separate components that were previously required to achieve each of these functions individually.
2Adaptability or versatility
If multiple separate components are used for outlets, then flexibility is improved, but manufacturing costs and time increase
Solution Approach 1:
The outlet components are merged into a single molded piece that includes the connection section, corrugated section, and sealing elements. This integration reduces the number of manufacturing steps from multiple separate productions and assemblies to a single molding process, significantly improving manufacturing efficiency.
Solution Approach 2:
The corrugated section is pre-formed as an integral part of the outlet during the molding process, rather than being added as a separate component afterward. This preliminary formation of the flexible section eliminates subsequent assembly steps and reduces manufacturing time.
3Reliability
If three welding operations are required per outlet, then connection reliability is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The outlet is designed as a single integrated component where the connection section, corrugated section, and heat exchanger connection are all part of the same molded piece. This integration reduces the number of welding operations from three separate welds to a single welding operation, simplifying manufacturing while maintaining connection reliability through the unified structure.
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 approach reduces manufacturing costs and improves handling and installation flexibility, while maintaining fluid tightness and pressure optimization, making it easier to connect fluid components like heat exchangers.
Implementation Method 1
the main tube and/or at least one of the outlets comprises an elastomer
Data Source
AI summary
A main line for distributing or collecting a medium, in particular a temperature control medium, has a main tube and at least three outlets. The outlets are connected to the main tube, wherein the outlets are each assigned to an opening of the main tube and are connected to the respectively assigned opening. The main tube comprises an axis A and defines an axial direction. The main tube and/or at least one of the outlets comprises an elastomer.