Flexible Distribution Pipe with Integrated Branch Interfaces

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Solution Overview

Problem

Existing distribution pipes for temperature control systems in automotive batteries require extensive assembly effort, are prone to leakage due to numerous connection points, and offer limited tolerance compensation and design flexibility.

Innovation Solution

The method involves creating openings in the wall of a one-piece main pipe section to integrate distributor interfaces, using a corrugator to form corrugated and smooth pipe sections, and attaching connector parts with radially projecting structures for material-bonded connections, allowing for tolerance compensation and reduced assembly complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple T-shaped intermediate pieces are inserted to create distributor interfaces, then the distribution functionality is improved, but the assembly effort and number of connection points increase

Engineering Contradiction:

Improvedistribution functionalityVSAvoidassembly effort

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the distributor interface directly into the main pipe by forming integral branch connections during the extrusion process. This eliminates the need for separate T-shaped intermediate pieces and reduces assembly operations while maintaining the distribution functionality across multiple branches.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The distributor interfaces are pre-formed as integral parts of the main pipe during the extrusion process. The branch connections are created in advance as part of the pipe manufacturing, eliminating the need for subsequent assembly operations and reducing overall assembly effort.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If multiple connection points are created for distributor interfaces, then the distribution capability is improved, but the susceptibility to leakage increases

Engineering Contradiction:

Improvedistribution capabilityVSAvoidleakage risk

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the distributor interfaces directly into the main pipe structure as integral connections. This eliminates separate connection points that would require assembly, thereby reducing the number of potential leakage sites while maintaining the distribution capability across multiple branches.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If smooth pipe sections are used for distributor interfaces, then the connection stability is improved, but the flexibility and tolerance compensation are reduced

Engineering Contradiction:

Improveconnection stabilityVSAvoidflexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent applies different wall structures at different locations: smooth pipe sections are used specifically at the distributor interface locations to ensure connection stability, while corrugated sections are used in the main pipe body to provide flexibility and tolerance compensation. This local differentiation resolves the contradiction between stability and flexibility.

Inventive Principle:

Principle #3Local quality

4Productivity

If intermediate sections are repeated periodically to reduce manufacturing costs, then the production efficiency is improved, but the assembly effort and susceptibility to leakage increase

Engineering Contradiction:

Improveproduction efficiencyVSAvoidassembly effort

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

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 assembly effort, minimizes leakage risk, enhances flexibility, and lowers costs by simplifying the manufacturing process while maintaining high stability and tolerance compensation.

Implementation Method 1

using a corrugator (28) to form corrugated and smooth pipe sections

Methodology Applied

Scientific EffectCorrugation: Corrugation

Implementation Method 2

attaching connector parts with radially projecting structures for material-bonded connections

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentEP3620704B2Method for producing an especially flexible distribution pipe

Publication Date: 2026.04.08 VOSS AUTOMOTIVE GMBH

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Figure 3~5
Figure 6~10

AI summary

The invention relates to a method for manufacturing a distribution pipe (1) for fluids, which comprises a main line (HS) in which corrugated pipe sections (2) having a corrugated wall (3) and/or smooth pipe sections (4) having a smooth wall (5) are arranged, wherein the respective wall (3, 5) encloses a free flow cross-section (Q) for the fluid, and wherein distributor interfaces (VS) for connecting secondary lines (NS) are located in the main line (HS).To overcome the disadvantages of the prior art, it is proposed that, in order to produce two or more distributor interfaces (VS), openings (6) are made in the wall (5) at two or more selected locations in a one-piece length section (LB) of the main line (HS), after which a connector part (7) is mounted at each of the selected locations, or after a connector part (7) has been mounted at each of the selected locations, wherein the connector part (7) has an inner channel (K) which is connected to the free flow cross-section (Q) of the main line (HS).