Hybrid Hose Coupling Element for High-Pressure Hydraulic Lines
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Solution Overview
Problem
Current coupling elements for high-pressure hydraulic lines are costly to produce and lack sufficient pressure resistance, making them unsuitable for applications exceeding 5 MPa due to their material limitations, particularly when using glass fiber-filled polyamide-based plastics.
Innovation Solution
A hybrid coupling element combining a high-strength plastic connector with a metallic support sleeve, where the plastic connector is injection molded with integrated projections and the metallic sleeve serves as a pressure carrier, allowing for cost-effective production and enhanced pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a glass fiber-filled polyamide-based plastic is used for the coupling element, then the production cost is reduced and manufacturing is simplified, but the pressure resistance is insufficient for high-pressure hydraulic lines exceeding 5 MPa
Solution Approach 1:
The patent applies composite materials by combining a plastic material (for cost-effective injection molding) with a metallic support sleeve (for pressure resistance). The plastic connector provides economical manufacturing through injection molding, while the metallic sleeve embedded within it provides the necessary strength to withstand high pressures exceeding 5 MPa, thus resolving the contradiction between ease of manufacture and pressure resistance.
Solution Approach 2:
The coupling element is segmented into two distinct functional components: a plastic connector that handles manufacturing and sealing functions, and a metallic support sleeve that handles pressure-bearing functions. This segmentation allows each material to be optimized for its specific role, with the plastic providing cost-effective production and the metal providing structural integrity under high pressure.
2Strength
If a metal coupling element is used, then the pressure resistance and strength are sufficient for high-pressure hydraulic lines, but the production cost increases due to complex shaping processes
Solution Approach 1:
The invention uses composite materials where the metallic support sleeve provides the necessary pressure resistance for high-pressure hydraulic applications, while the plastic connector enables cost-effective injection molding production. This composite structure eliminates the need for expensive metal shaping processes while maintaining sufficient strength.
Solution Approach 2:
The invention extracts the pressure-bearing function from the entire coupling element and assigns it specifically to the metallic support sleeve, while the plastic connector handles manufacturing and sealing functions. This extraction allows the use of cheaper plastic for the majority of the component while using metal only where structurally necessary.
3Strength
If a hybrid component with metallic support sleeve is used, then the pressure resistance is enhanced for high-pressure applications, but the device complexity increases due to multiple materials and connection methods
Solution Approach 1:
The patent merges the metallic support sleeve and plastic connector into a single integrated hybrid component through injection molding, where the plastic is injected around the metal sleeve in one process step. This combining approach reduces assembly steps and creates a unified structure that functions as a single unit, thereby reducing overall device complexity despite using multiple materials.
Solution Approach 2:
The plastic material acts as an intermediary that bonds the metallic support sleeve to the external environment and sealing surfaces. This intermediary material facilitates the integration of dissimilar materials (metal and plastic) into a cohesive structure, managing the complexity of multi-material construction through a unifying bonding medium.
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 hybrid coupling element provides a cost-effective solution with improved pressure resistance and durability, meeting the requirements for high-pressure hydraulic applications while maintaining a lightweight design and allowing for targeted material selection, ensuring long service life and resistance to hydraulic media.
Implementation Method 1
The support sleeve of the connecting piece, which is preferably made of metal, serves as a pressure carrier and can generate the necessary counterforce when pressing the press socket onto the coupling element provided with the high-pressure hydraulic hose.
Implementation Method 2
The shape of the coupling element according to the invention, i.e. a desired external structure, is given to the connecting piece of the coupling element during its manufacture, namely during an injection molding process. For this purpose, the plastic is injected into an injection mold.
Implementation Method 3
During this injection molding process, the metal carrier sleeve connects to the plastic connector and a finished hybrid component can be removed from the injection mold.
Data Source
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AI summary
The invention relates to a coupling element for a hose coupling, consisting of a tubular connecting piece that can be connected to a fitting at its front end (11) and has a hose nipple (31) at its other end, the insertion end (12), for holding a slide-on high-pressure hose. The connecting piece is a hybrid component consisting of a plastic fitting (30) and a support sleeve (40) that serves as a pressure carrier. Both components (30, 40) of the connecting piece are permanently joined together. This coupling element for hose couplings can be manufactured cost-effectively and is particularly suitable for use with high-pressure hydraulic lines.