Metal-Plastic Composite Hydraulic Block for Brake Systems
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Solution Overview
Problem
Conventional hydraulic blocks for brake pressure control systems require extensive machining and straight connecting lines, limiting design flexibility and increasing production complexity.
Innovation Solution
A metal-plastic composite hydraulic block where a metal part with brake line ports, valve receptacles, and connecting lines is embedded in a plastic part, allowing for reduced machining and complex line routing, including curved and angled connecting lines that terminate inside the block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to produce hydraulic blocks, then manufacturing precision can be achieved, but extensive material removal is required increasing production complexity and time
Solution Approach 1:
The metal insert is pre-formed with the complex internal geometry, brake line ports, and connecting lines before being integrated into the final hydraulic block. This preliminary formation of complex features eliminates the need for extensive post-processing machining operations, directly resolving the contradiction between achieving manufacturing precision and maintaining production efficiency
Solution Approach 2:
The hydraulic block combines a metal insert (providing precise hydraulic features) with a plastic housing (providing structural support). This composite approach allows the metal insert to be formed with high precision through casting or additive manufacturing, while the plastic housing can be molded simultaneously, dramatically reducing overall production time and complexity compared to traditional all-metal machining
2Ease of manufacture
If straight connecting lines are used in conventional hydraulic blocks, then manufacturing is simpler, but design flexibility is limited
Solution Approach 1:
The complex curved connecting lines and internal geometry are pre-formed in the metal insert during the casting or additive manufacturing process, eliminating the need for subsequent machining operations. This preliminary formation enables design flexibility for complex line routing without compromising manufacturing simplicity
Solution Approach 2:
The invention changes the manufacturing parameters and methods by transitioning from subtractive machining to formative processes like casting or additive manufacturing. This parameter change enables the production of complex curved connecting lines and internal geometries that would be difficult or impossible to achieve through traditional machining, thereby increasing design flexibility while maintaining ease of manufacture
Data Source
AI summary
A hydraulic block for a hydraulic assembly of a slip control system of a hydraulic vehicle brake system includes a metal-plastic composite part with a metal part and a further part. The metal part includes sleeve-like brake line ports, sleeve-like valve receptacles, sleeve-like pump receptacles, and pipes as connecting lines. The further part is a plastic part that is injection-molded around the metal part to form the hydraulic block in a cuboid shape.