Fluid Line Elbow Insert for Smooth Inner Flow Paths
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Solution Overview
Problem
Existing fluid line elbows, especially those made of plastic, face challenges in achieving good flow properties due to manufacturing methods that result in edges and abrupt transitions, and require complex assembly processes.
Innovation Solution
A fluid line elbow design where the insert part, comprising a curved section, is separately manufactured and overmolded onto a remaining elbow part, using high-temperature plastic and pivotable cores to create a smooth, continuous inner wall, ensuring a constant inner diameter and improved flow properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding with cores is used to manufacture fluid line elbows, then manufacturing simplicity is maintained, but edges and abrupt transitions are created on the radially inner side of curved sections, degrading flow properties
Solution Approach 1:
The fluid line elbow is divided into two parts: an insert part containing the curved section with smooth inner wall, and a remaining elbow part. The insert part is manufactured separately using pivotable cores to achieve smooth contours, then integrated into the remaining elbow part through overmolding or other joining methods. This segmentation allows the curved section to be formed with high precision without requiring complex core mechanisms in the main molding process.
Solution Approach 2:
The insert part is pre-manufactured with the desired smooth curved geometry before being integrated into the final elbow assembly. By preparing the smooth-contoured insert in advance, the need for complex pivotable cores during the main injection molding process is eliminated, simplifying the overall manufacturing while achieving high flow properties.
2Adaptability or versatility
If thermally forming plastic fluid lines is used to create curved sections, then custom installation adaptability is achieved, but assembly effort and time are significantly increased
Solution Approach 1:
The curved section with precise geometry is pre-formed in the insert part during manufacturing, eliminating the need for post-manufacturing thermal forming and shaping operations. The insert is ready-to-install with the exact curvature needed, reducing assembly time while maintaining installation adaptability.
3Ease of operation
If prefabricated diverter pieces are used, then assembly effort is reduced, but flow properties are degraded due to manufacturing limitations
Solution Approach 1:
By separating the curved section into a distinct insert part that can be manufactured with specialized tools (pivotable cores), the invention achieves high flow properties that would be impossible with conventional single-step molding of prefabricated pieces, while still maintaining simple assembly through the overmolding process.
Solution Approach 2:
The insert part is specifically designed with optimized local geometry in the curved section to achieve superior flow properties, while the remaining elbow part maintains standard features for easy assembly. This localized optimization allows high-performance curved sections without compromising overall assembly simplicity.
Data Source
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AI summary
The present invention relates to a fluid line elbow (10) which defines a fluid flow channel (12) inside, wherein the fluid flow channel (12) opens at at least a first and a second opening towards an outside of the fluid line elbow (10) so that fluid can enter or exit the fluid flow channel (12), wherein the fluid flow channel (12) has a first section (14) associated with the first opening, which extends substantially straight, a second section (16) associated with the second opening, which extends substantially straight, and a third section (18) which is curved between the first section (14) and the second section (16), wherein a central axis (X) defined by the first section (14) is arranged at an angle to a central axis (Y) defined by the second section (16).and wherein the fluid line elbow (10) comprises a pre-fabricated insert which, within its interior, defines at least section by section the third section (18) of the fluid flow channel (12).