Hybrid Fluid Housing Exoskeleton for Mechanical Stability
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Solution Overview
Problem
Existing fluid treatment modules in internal combustion engines face challenges in mechanical stability and functionality, particularly due to the limitations of plastic materials under mechanical loads and assembly forces, which hinder the use of fully plastic components in high-stress applications.
Innovation Solution
A hybrid fluid treatment module design incorporating a plastic housing part with an externally positioned support structure that forms an exoskeleton, providing reinforcement to critical areas like the housing connecting section, allowing for better force transmission and reducing the mechanical load on the plastic material, while maintaining easy assembly and serviceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If plastic material is used for the housing part, then weight and manufacturing costs are reduced, but mechanical stability and strength under mechanical loads are insufficient
Solution Approach 1:
The patent applies composite materials by combining plastic housing parts with a metal support structure (exoskeleton) to create a hybrid construction. The metal support structure provides the necessary mechanical strength and load-bearing capacity, while the plastic housing maintains weight reduction and cost advantages. This composite approach resolves the contradiction by integrating materials with complementary properties.
2Ease of manufacture
If plastic material is used for the housing part, then manufacturing costs are reduced, but mechanical stability under assembly forces is insufficient
Solution Approach 1:
The housing module is segmented into distinct functional components: a plastic housing part for cost-effective manufacturing and fluid containment, and a separate metal support structure for mechanical stability and assembly force resistance. This segmentation allows each material to be optimized for its specific function while working together as an integrated system.
Solution Approach 2:
The hybrid construction combining plastic and metal materials resolves the contradiction between manufacturing cost and mechanical stability. The plastic housing can be manufactured using cost-effective injection molding, while the metal support structure provides the necessary mechanical stability under assembly forces.
3Ease of manufacture
If fully plastic components are used, then weight is reduced and costs are lowered, but reliability in high-stress applications deteriorates
Solution Approach 1:
The patent employs composite materials to achieve both manufacturing simplicity and reliability. The plastic housing maintains ease of manufacture through injection molding, while the integrated metal support structure ensures reliability in high-stress applications by providing superior mechanical properties and load-bearing capacity.
Solution Approach 2:
The metal support structure is strategically positioned at critical locations where mechanical strength and reliability are most needed, such as the connecting section between housing parts. This local reinforcement approach maintains manufacturing simplicity while significantly improving reliability in high-stress areas.
Data Source
AI summary
A housing module of a fluid treatment module of a fluid system is provided with a fluid housing with inlet and outlet for fluid. The fluid housing has a housing part with a receiving chamber for a fluid treatment component for treatment of fluid and an installation opening, closable by a housing closure part, for installation of the fluid treatment component in the receiving chamber. A housing connecting section is provided for connecting the housing part and the housing closure part to each other. The housing module has an externally positioned support structure that surrounds the housing part like a sleeve and has a reinforcement region that extends about the housing connecting section. The support structure has a fastening region for attachment of the housing module on a holding component of the fluid system. The connection of the housing part with the housing closure part is a direct connection.