Friction Welding Connector Melt Extraction

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Solution Overview

Problem

Friction welding in connecting lines leads to contamination from abrasion particles formed during the process, which is particularly harmful in fuel lines, as the melt produced escapes into the line interior in the form of granulate, causing safety issues and requiring post-weld cleaning.

Innovation Solution

A device with recesses and radial openings is used to control and withdraw excess melt from the friction welding area, guiding it away from the connector edges and reducing pressure, thereby preventing contamination. The device includes longitudinal, angled, or spiral recesses and equidistantly spaced radial openings to manage melt flow and pressure effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If friction welding is used to connect lines, then connection strength and automation capability are improved, but abrasion particles are formed that contaminate the line interior

Engineering Contradiction:

Improveconnection strengthVSAvoidline contamination

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the harmful melt from the welding zone by providing withdrawal means (radial openings and recesses) that remove the melt produced during friction welding from its area of origin, preventing it from contaminating the line interior while maintaining the welding connection strength

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the harmful melt that would otherwise contaminate the line into a beneficial controlled flow that can be directed away from critical areas. The melt is channeled through recesses to form a protective joint between the connecting device and line, transforming the contaminant into a bonding agent

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If friction welding is performed, then manufacturing efficiency is improved, but post-weld cleaning is required to remove contamination

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidpost-weld cleaning time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The melt that would require cleaning is converted into a beneficial joint-forming material. By channeling the melt through recesses, it solidifies to create a protective bond between components, eliminating the need for post-weld cleaning operations and maintaining high manufacturing efficiency

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The welding process itself serves the dual purpose of creating the connection and forming the protective joint. The melt produced during welding automatically flows into the recesses and solidifies to create the joint, making the process self-sufficient and eliminating separate cleaning steps

Inventive Principle:

Principle #25Self-service

3Strength

If melt is produced during friction welding, then welded joint is formed, but uncontrolled melt spread occurs due to high pressure

Engineering Contradiction:

Improvewelded joint formationVSAvoidmelt pressure control

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent introduces recesses as intermediary structures that mediate between the high-pressure melt generation zone and the external environment. These recesses provide a controlled path for melt evacuation, preventing uncontrolled spread while maintaining the pressure needed for welded joint formation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the pressure parameters by providing escape paths through radial openings and recesses. This allows the system to maintain high pressure for welding where needed while providing pressure relief through the withdrawal means, controlling the melt behavior without compromising joint strength

Inventive Principle:

Principle #35Parameter changes

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 solution significantly reduces contamination within the lines, enhances safety, particularly in automotive applications, and automates the manufacturing process by eliminating the need for post-weld cleaning, while ensuring a stable connection through controlled melt formation and distribution.

Implementation Method 1

joining the line end (2) with the connector (1) by means of friction welding

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

melt producible by the friction welding

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS9346215B2Device, arrangement and method for connecting lines, motor vehicle including such a device or arrangement, respectively

Publication Date: 2016.05.24 HDT VERITAS HESSEN GMBH

AI summary

The invention relates to an device for connecting lines, especially to a quick connector, comprising at least one connector adapted to be joined with a line end by means of friction welding. A controlled release of excess melt is achieved by that the connecting device is provided with means for withdrawing the melt producible by the friction welding from the its area of the origin.