Fuel Line Connector Reinforced Inner Core
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Solution Overview
Problem
Existing fuel line connectors often fail to provide a reliable fluid-tight seal and sufficient resistance against axial separation, leading to issues like jamming and structural failures under pull-apart forces.
Innovation Solution
A fuel line connector assembly with a one-piece connector body featuring a ramp and inner core, where the inner core extends through the ramp and into a sacrificial portion, providing reinforcement and enhancing the retaining surface's strength through coinjection molding, allowing for improved resistance to axial separation forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connector body is made with a single material, then the manufacturing process is simple, but the resistance against axial separation is insufficient
Solution Approach 1:
The connector body is made from two different materials: a first material for the outer skin and a second material for the inner core. The inner core material is selected to have different properties than the outer skin material, specifically providing enhanced strength and resistance to axial separation forces while the outer skin provides sealing and structural integrity.
2Strength
If the inner core extends through the entire ramp, then the retaining surface strength is improved, but the manufacturing complexity increases
Solution Approach 1:
A sacrificial portion of the inner core is formed extending through the ramp during the molding process. This sacrificial portion is later removed to expose the apex of the ramp, creating the final configuration where the inner core extends through the ramp without requiring complex multi-step molding operations.
3Strength
If a multi-piece connector is used, then the structural strength is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The outer skin and inner core are combined into a single integrated connector body formed by co-injection molding. This merging of components maintains the strength benefits of multi-material construction while eliminating the assembly complexity and potential leakage issues associated with multiple separate parts.
4Force
If the ramp has a large radius of curvature, then the insertion force is reduced, but the axial separation resistance is compromised
Solution Approach 1:
The combination of outer skin and inner core materials allows the ramp to have an optimized radius of curvature that reduces insertion force while the reinforced apex region, created by extending the inner core through the ramp, provides sufficient resistance to axial separation forces.
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 connector assembly achieves a fluid-tight seal and superior performance in axial pull-apart tests, reducing jamming and structural failures, while maintaining lower insertion forces and preventing breakage during use.
Implementation Method 1
The molding step may comprise coinjection molding the connector body
Data Source
Figure 1~4
Figure 2~6
AI summary
A method of making a connector (20) for a fluid line connector assembly (10), comprising the steps of: molding a connector body having a ramp (80) with an outer skin (102) and an inner core (100), wherein the inner core (100) extends through the ramp (80) to a sacrificial portion (104) formed at least partially from the outer skin (102); and severing the sacrificial portion (104) from the ramp (80). The molding step further comprises molding the connector body as a one-piece body having a generally cylindrical shape that extends axially from one axial end to the ramp (80) which is located at a second axial end, with the ramp (80) extending radially outwardly to the sacrificial portion (104).