Flexible Rigid Pipe Transition Connector Sealing
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Solution Overview
Problem
Existing connection systems for flexible and rigid pipes in new-energy vehicles fail to withstand high pressure and temperature variations, leading to sealing issues and reduced endurance mileage due to material deformation and leakage.
Innovation Solution
A system comprising a flexible metal corrugated pipe, transition connectors with a thickened wall, and buckling sleeves coated with a rubber layer, where the buckling sleeves are positioned outside the transition connectors to prevent radial stress on the pipe, enhancing axial tensile resistance and sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional flexible pipe assemblies are used in heat pump air-conditioners, then the system can accommodate high and low temperature alternations, but the pipes cannot withstand high pressure (170-300 bar) and high temperature (up to 180°C), leading to sealing failures
Solution Approach 1:
The flexible pipe assembly uses a composite structure with a metal corrugated pipe (stainless steel or aluminum alloy) as the inner layer for pressure resistance, and a rubber layer as the outer layer for flexibility and sealing. This composite material approach allows the pipe to withstand both high pressure (up to 300 bar) and high temperature (up to 180°C) while maintaining sealing performance in heat pump air-conditioner systems.
2Reliability
If rigid pipes are used solely for connection, then sealing performance can be ensured, but the internal space limitation of vehicles prevents their use due to lack of flexibility
Solution Approach 1:
The invention creates a hybrid pipe assembly that combines rigid metal corrugated pipe sections (for structural strength and sealing) with flexible rubber coating and connection mechanisms (for adaptability). This composite structure enables the pipe to maintain reliable sealing while providing the flexibility needed to accommodate vehicle internal space constraints and routing requirements.
3Strength
If heating wires are used to replace flexible pipe assemblies, then high temperature and high pressure resistance is achieved, but heating efficiency decreases significantly, reducing vehicle endurance mileage
Solution Approach 1:
The invention replaces energy-intensive heating wires with a thermally efficient heat exchanger system using flexible pipe assemblies that can withstand high pressure and temperature. The metal corrugated pipe with rubber coating provides both mechanical strength for pressure resistance and thermal conductivity for efficient heat transfer, eliminating the need for resistive heating and significantly improving vehicle heating efficiency and endurance mileage.
4Reliability
If connection structures use sealing rings and rubber materials, then sealing is achieved, but aging under high and low temperature atmospheres causes air leakage
Solution Approach 1:
The connection structure uses a composite sealing system combining metal corrugated pipe sections (for structural stability and pressure resistance) with specially formulated rubber materials that resist aging under extreme temperature conditions. The metal-rubber composite construction provides both immediate sealing effectiveness and long-term durability, preventing air leakage even after prolonged exposure to high and low temperature cycling in heat pump air-conditioner operations.
5Strength
If stainless steel materials are deformed during buckling to achieve connection, then assembly is secured, but martensite or austenite twins form causing cracks and leakage
Solution Approach 1:
The connection structure is segmented into distinct functional zones: a metal corrugated pipe section for structural connection and stress absorption, and a rubber-coated sealing section for leakage prevention. The buckling deformation is localized to the corrugated metal section which is designed to deform controllably without forming harmful martensite or austenite twins, while the rubber-coated section maintains its sealing integrity and prevents leakage at the connection point.
Data Source
AI summary
A system for connecting and sealing flexible and rigid pipes under high pressure comprises a flexible pipe, rigid pipes, and transition connectors, wherein two ends of each transition connector are respectively connected with the flexible pipe and one rigid pipe, external sides of the flexible pipe and the transition connectors are coated with a rubber layer, buckling sleeves are buckled on the rubber layer outside the transition connectors, aluminum alloy connectors are embedded into external surfaces, extending out of the rubber layer, of the transition connectors, and external buckling sleeves are buckled on external surfaces of the aluminum alloy connectors.