Injection-Molded Fluid Line Connector for Leak-Tight Coupling
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Solution Overview
Problem
The production of fluid lines with connecting elements, such as VDA couplings, is complex and costly due to the need for separate manufacturing of coupling plugs, welding or soldering, and subsequent leak testing, which also complicates corrosion protection and rotation prevention.
Innovation Solution
A method and device using an injection-molding process to form the coupling part and connector directly on the fluid line, eliminating the need for separate components and subsequent assembly, with a mandrel and bell structure to calibrate and seal the connector, allowing for one-piece production and avoiding leak testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate coupling plugs are manufactured by turning and milling and then welded or soldered to the fluid line, then the connecting element can be formed, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines the fluid line and coupling part into a single integrated component produced by injection molding. The coupling part is formed directly on the fluid line during the injection molding process, eliminating the need for separate manufacturing of coupling plugs and subsequent welding or soldering operations. This merging of components resolves the technical contradiction by simplifying manufacturing while maintaining sealing integrity through the monolithic structure.
Solution Approach 2:
The patent replaces traditional mechanical joining methods (turning, milling, welding, soldering) with an injection molding process. The coupling part is formed by injecting plastic material directly onto the fluid line in a single manufacturing step, substituting complex mechanical assembly operations with a streamlined molding process that inherently ensures sealing.
2Ease of manufacture
If welding or soldering processes are used to attach the coupling plug to the fluid line, then the connecting element is formed, but additional corrosion protection treatments are required
Solution Approach 1:
The patent uses composite material construction where a plastic coupling part is injection molded directly onto the fluid line. This composite structure eliminates the need for metal-to-metal joining (welding/soldering) that would require subsequent corrosion protection. The plastic material provides inherent corrosion resistance, resolving the contradiction by eliminating the harmful factor while simplifying the manufacturing process.
3Stability of the object's composition
If rotation prevention means are added to the coupling plug, then rotational stability is achieved, but additional manufacturing effort is required
Solution Approach 1:
The patent incorporates asymmetric features directly into the injection-molded coupling part to prevent rotation. The asymmetric geometry is formed during the molding process itself, integrating the rotation prevention function into the basic component structure without requiring separate parts or additional assembly steps. This resolves the contradiction by achieving rotational stability while maintaining manufacturing simplicity.
4Ease of manufacture
If separate components are assembled to form the connecting element, then the connection is formed, but leak testing becomes necessary
Solution Approach 1:
The patent merges the fluid line and coupling part into a single injection-molded component, eliminating joints and interfaces where leaks could occur. The monolithic structure inherently prevents leakage without requiring separate assembly operations or subsequent leak testing, resolving the contradiction by improving reliability while simplifying manufacturing.
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 significantly reduces manufacturing costs and effort by eliminating welding and soldering processes, corrosion protection treatments, and leak testing, while providing a leak-tight and rotationally secure connection.
Implementation Method 1
it is then possible, in a subsequent step, to inject into the cavity the intended plastic for forming the coupling part on the fluid line in an injection-molding process
Implementation Method 2
to inject into the cavity the intended plastic for forming the coupling part on the fluid line in an injection-molding process and to allow said plastic to harden
Data Source
AI summary
The invention relates to a method and a device for producing a fluid line (7) with a connecting element formed on an end portion of the fluid line (7), wherein the connecting element comprises a coupling part (8) and a connector (70) which connects to the coupling part (8) toward the end of the fluid line.