Flexible Valve Array Connector for Gas-Tight Misalignment Tolerance
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Solution Overview
Problem
The assembly of plug connectors between valve arrays and supply blocks in the automotive industry is cumbersome and unreliable, particularly when manufacturing tolerances and alignment discrepancies are present, making it difficult to establish a gas-tight connection.
Innovation Solution
A connecting element made of flexible material with conical engagement elements that can self-center and align with the supply block, allowing for a simplified and reliable gas-tight connection between valve inlets and tubes, and a supply block with rigid engagement elements that compensate for alignment discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid plug connector is used to connect valve arrays to supply blocks, then manufacturing precision can be maintained, but assembly difficulty increases and alignment tolerance decreases
Solution Approach 1:
The connecting element uses a flexible material body that can deform during assembly to accommodate misalignment between valve inlets and supply block ports, while the engagement elements maintain the connection geometry. This flexibility allows the connector to adapt to manufacturing tolerances and assembly variations, making installation easier without sacrificing connection precision.
Solution Approach 2:
The patent changes the physical state of the connecting element from rigid to flexible, allowing it to undergo elastic deformation during assembly. This parameter change enables the connector to absorb alignment errors and accommodate manufacturing tolerances, simultaneously improving ease of assembly while maintaining connection precision through the flexible material's ability to return to its original shape.
2Ease of operation
If a flexible connecting element is used to accommodate misalignment, then assembly ease improves, but connection reliability may deteriorate
Solution Approach 1:
The connecting element is segmented into distinct functional zones: a flexible body portion that accommodates misalignment through deformation, and rigid engagement elements at each end that maintain precise connection geometry. This segmentation allows the flexible portion to absorb assembly variations while the engagement elements ensure reliable, gas-tight connections to both the valve inlets and supply block ports.
Solution Approach 2:
The flexible material body acts as a compliant intermediary that deforms during assembly to accommodate misalignment, then maintains the connection through its elastic recovery. This flexible shell approach allows the connector to adapt to manufacturing tolerances while the engagement elements provide stable, reliable connection points that ensure gas-tight sealing.
3Reliability
If engagement elements are made rigid to ensure gas-tight connection, then connection reliability improves, but adaptability to misalignment decreases
Solution Approach 1:
The flexible material body serves as an adaptive intermediary that deforms to accommodate misalignment between rigid engagement elements. This flexible shell allows the rigid engagement elements to maintain their precise geometry for gas-tight connections while the flexible body absorbs the alignment errors, combining reliability with adaptability.
Solution Approach 2:
The connecting element is divided into rigid engagement elements for reliable connection and a flexible body portion for adaptability. This segmentation allows each part to perform its specialized function: the rigid engagement elements ensure gas-tight sealing, while the flexible body accommodates misalignment and absorbs assembly variations.
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
Facilitates easy and reliable assembly of valve arrays with pre-assembled connecting elements, ensuring a gas-tight connection without the need for tools, reducing misalignment issues and simplifying the installation process.
Implementation Method 1
the connecting element is made of a flexible material or includes a flexible material... the shape and/or alignment of the second engagement elements can be changed at least slightly by the action of force without damage and without a permanent change in shape
Data Source
AI summary
A connecting element for connecting ports of a valve array's valve attachment block to a supply block may include first engagement elements on one side for establishing a connection to the ports, and second engagement elements on another side for establishing a connection to the supply block. The first and second engagement elements may be configured to establish gas-tight connections, wherein the connecting element includes a flexible material. In a further combination, the supply block has an attachment side for attaching tubes to the supply block and a connection side for connecting the supply block to the connecting element, the connection side having engagement elements which are engageable with the second engagement elements of the connecting element for establishing a gas-tight connection. The supply block may be less flexible than the connecting element. A further combination may include the valve array.