Fluid Line Connector Structure for Mixed-Temperature Sealing
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Solution Overview
Problem
Existing devices for connecting fluid-carrying lines in the commercial vehicle and automotive industries, particularly for urea-water mixtures, face challenges in achieving a compact, cost-effective, and temperature-resistant connection while ensuring media resistance and tightness, especially when lines are used in different temperature ranges and require heating.
Innovation Solution
A device with opposing line receptacles designed for lines of different materials, allowing for sealing and flexible connection through adhesive, welding, or crimping methods, along with integrated heating circuits and a housing for environmental protection, enabling separate temperature control and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single intermediate connection is used to connect two fluid-carrying lines, then the connection structure is simplified, but it is difficult to accommodate lines with different temperature requirements and material properties
Solution Approach 1:
The connection device is segmented into two separate receptacles (first line receptacle and second line receptacle), each capable of independently accommodating fluid-carrying lines with different material properties and temperature requirements. This segmentation allows each receptacle to be optimized for specific line types while maintaining a unified overall structure.
Solution Approach 2:
The connection device is designed with universal adaptability by providing multiple receptacles that can handle different types of fluid-carrying lines (heatable and non-heatable) within a single device. The device structure allows it to perform multiple functions: connecting lines with different materials, accommodating different temperature ranges, and providing various connection methods (adhesive, welding, crimping) through the same basic receptacle design.
2Reliability
If adhesive is used to fix the lines in the annular space, then the connection is secure and sealed, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
An adhesive is introduced as an intermediary substance between the fluid-carrying line and the connection device structure. The adhesive fills the annular space and creates a reliable bond and seal between the line's outer cross-section and the device, ensuring both mechanical fixation and fluid tightness while accommodating the flexibility of hose-like lines.
Solution Approach 2:
The invention provides multiple connection parameter options: adhesive bonding, welding, or crimping. This allows the manufacturing process to be optimized by selecting the most appropriate method based on specific requirements, balancing reliability and productivity. The annular space design accommodates all these methods by providing a confined area for connection.
3Temperature
If heating circuits are integrated in the area of the hose coupling, then the lines can be heated effectively, but the device complexity and manufacturing cost increase
Solution Approach 1:
Heating circuits are integrated locally within the connection device structure, specifically in the area of the hose coupling where heat is most needed. This localized heating approach provides effective temperature control for the fluid-carrying lines without requiring a complex system-wide heating solution, reducing overall device complexity while maintaining necessary thermal management capabilities.
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
The solution provides a secure, compact, and cost-effective connection for fluid-carrying lines across varying temperature ranges, ensuring media resistance and tightness without additional intermediate connections, while allowing for efficient heating and reduced production costs by using lines suited to specific temperature requirements.
Implementation Method 1
each of the fluid-carrying lines is fixed by means of an adhesive that at least partially fills the annular space
Implementation Method 2
each of the fluid-carrying lines is fixed in the annular space by friction welding, ultrasonic welding, or laser welding
Implementation Method 3
each of the fluid-carrying lines is connected to the second part by means of a crimp connection
Implementation Method 4
The first fluid-carrying line is designed for use in a higher temperature range T1 of -40°C to 200°C
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a device (1) for connecting two fluid‑channelling lines (10, 20), wherein the device has a through‑bore (2) for advancing the fluid and two opposite line mounts (11, 21), which terminate at a predetermined distance (4) from one another within the device. Each of these line mounts (11, 21) is designed such that it is provided with a first part (12, 22), through which the through‑bore (2) leads, and a second part (13, 23), which encloses the first part (12, 22), an annular space (14, 24) therefore being formed between the first part (12, 22) and the second part (13, 23). Each of the two fluid‑channelling lines (10, 20) is arranged in one of the line mounts (11, 21) such that it has an inner cross section (16, 26) arranged, and fixed, with sealing action against the first part (12, 22) of the device and has an outer cross section (17, 27) arranged, and fixed, in the annular space (14, 24).