Heating/Cooling Manifold Plastic Welding for Damage-Free Assembly
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Solution Overview
Problem
The existing heating/cooling system manifolds face challenges in mounting due to the rotational movement required for connecting tubular metal elements, which can damage O-rings and complicate the sealing process.
Innovation Solution
A heating/cooling system manifold with a sleeve made of heat-resistant material and plastic fixing means connected by a welding seam, eliminating the need for rotational movement and allowing for easy access and inspection of the welding seam, which is arranged outside the sleeve, facilitating a secure and efficient assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tubular metal elements are used for fixing means and connected by screw connection, then the connection is strong and durable, but rotational movement is required which can damage O-rings and complicate the sealing process
Solution Approach 1:
The patent replaces the mechanical screw connection system with an ultrasonic welding system. The fixing means are made of plastic material that can be welded by ultrasonic vibration, eliminating the need for rotational movement and screw threads. This substitution resolves the contradiction by maintaining strong connection while simplifying the sealing process, as no rotation is needed and O-rings are not subjected to rotational damage.
Solution Approach 2:
The patent changes the material parameter of the fixing means from metal to plastic, and changes the connection method parameter from mechanical screwing to ultrasonic welding. This parameter change enables the connection process to be performed without rotation, thereby protecting O-rings while still achieving strong, durable connections through the welding process.
2Strength
If fixing means are made of metal material, then the connection is strong, but the material usage is heavier and more complex to process
Solution Approach 1:
The patent employs plastic material for the fixing means instead of traditional metal materials. This material substitution achieves sufficient connection strength through ultrasonic welding while significantly reducing the weight of the fixing means. The plastic material can be effectively joined by ultrasonic vibration, providing both strength and weight reduction simultaneously.
3Reliability
If the welding seam is arranged inside the sleeve, then the connection is protected, but the heating and inspection of the welding seam becomes difficult
Solution Approach 1:
The patent inverts the conventional arrangement by placing the welding seam outside the sleeve rather than inside. This inversion makes the welding seam easily accessible for ultrasonic heating and simple to inspect visually, while still providing adequate protection through the structural design of the fixing means and sleeve assembly. The external positioning resolves the contradiction by enabling easy manufacturing and inspection while maintaining reliability.
4Reliability
If multiple parts need to be sealed against the sleeve, then comprehensive sealing is achieved, but the sealing process becomes more complicated
Solution Approach 1:
The patent merges the sealing function into a simplified structure where the plastic fixing means with integrated O-ring grooves directly seal against the sleeve. By combining the fixing function and sealing function into a single integrated component design, the patent achieves comprehensive sealing while reducing the complexity of the sealing process. Only two parts (the fixing means and the sleeve) need to be sealed against each other, simplifying the overall sealing structure.
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 enables simplified and damage-free mounting of the manifold, ensuring effective sealing and reduced material usage while allowing for precise positioning and low-weight construction, thus enhancing the assembly efficiency and reliability of the heating/cooling system.
Implementation Method 1
For the welding connection it is only necessary to heat the plastic parts at least in the area at which they contact each other, for example by ultra-sonic heating
Data Source
Figure 1~2
Figure 3a~5b
AI summary
A heating/cooling system manifold (1) is shown comprising a sleeve (2) having at least one opening in a circumferential wall and fixing means (5) having a connection geometry for fixing a functional part (9) of the system to the sleeve (2) and being arranged around the opening. It is intended to facilitate mounting of the manifold. To this end the sleeve (2) is made from a heat resistant material and the fixing means (5) comprise at least to parts (6, 7) made of a plastic material which are connected by a welding seam (8).