Single-Piece Hydroformed Pipe Fitting with Integrated Press and Threaded Connections
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Solution Overview
Problem
Existing methods for manufacturing press-fittings are costly and inefficient, often requiring multiple costly steps such as machining, joining, or specific die-forming techniques that limit the production of different connection types.
Innovation Solution
A single-piece fitting is produced through forming, combining a press-fit connection with a ring-shaped seat and a threaded connection using hydroforming or cold forging, allowing for minimal material use and easy assembly with known tools, eliminating the need for joining processes like cementing or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to produce press-fitting elements, then manufacturing precision can be achieved, but production cost increases and material waste occurs
Solution Approach 1:
The patent replaces traditional mechanical machining processes with hydroforming technology. A hollow cylindrical blank is subjected to high-pressure fluid (water) that plastically deforms the material into the desired fitting shape with integrated press-fitting sections. This substitution eliminates cutting operations, reduces material waste, and lowers production costs while maintaining manufacturing precision through controlled plastic deformation.
Solution Approach 2:
The invention changes the material state and processing parameters by using hydroforming instead of machining. The high-pressure fluid transforms the physical state of deformation from incremental cutting to simultaneous plastic flow, enabling complex geometries to be formed in a single operation. This parameter change reduces the number of manufacturing steps and improves cost-effectiveness.
2Adaptability or versatility
If multiple connecting pieces are joined by cementing or welding to create a fitting, then different connection types can be achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple separate connecting pieces into a single integrated fitting structure formed by hydroforming. The process creates a monolithic component with multiple press-fitting sections and threaded connections formed simultaneously from one hollow cylindrical blank, eliminating the need for separate joining operations like cementing or welding. This integration reduces manufacturing complexity while maintaining versatility in connection types.
Solution Approach 2:
The invented fitting serves multiple functions within a single component. The hydroforming process creates a universal fitting that can accommodate different connection types (press-fitting sections for rigid or flexible pipes, threaded connections) in one integrated structure, allowing a single component to perform what previously required multiple assembled parts.
3Productivity
If traditional die-forming methods are used to create press fittings, then press-fit connections can be produced, but the ability to produce other connection types is limited
Solution Approach 1:
The hydroforming process creates a universal manufacturing capability that can produce multiple connection types from a single blank. The fitting includes press-fitting sections for high-speed production, as well as threaded connections and other joining features, all formed in one operation. This multi-functionality maintains the productivity benefits of forming while expanding the range of producible connection types.
Solution Approach 2:
The invention segments the fitting into multiple functional zones within a single formed component. Different sections of the hydroformed fitting have different geometries optimized for different connection types (press-fitting zones, threaded zones), allowing diverse connection capabilities while maintaining the efficiency of a single-forming process.
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 approach enables efficient production of fittings with various connection types using fewer steps and less material, reducing costs and improving manufacturing efficiency while maintaining ductility with materials like copper or steel.
Implementation Method 1
The hydroforming method is preferably used to form the pipe section, in which forming takes place under pressure with a fluid.
Implementation Method 2
forming can take place both at room temperature as well as in a heated state. Cold forging can also be used, depending on the geometry of the part.
Data Source
AI summary
A fitting for connecting pipes together. The fitting includes a press-fit connection including a ring-shaped seat configured to receive at least one of sealing and holding elements. The fitting is configured to be sealingly connected to an inserted pipe end. A threaded connection is configured to be connected to a pipe by a thread on the threaded connection. The fitting is a single piece and is devoid of weldments.