Injection Molded Coupling Head for Pneumatic Brake Systems
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Solution Overview
Problem
Existing coupling heads for pneumatic brake systems in towing vehicles and trailers are costly and labor-intensive to manufacture due to the need for manual assembly of components and fittings.
Innovation Solution
The coupling head is designed as a one-piece injection molded part made of plastic, where the housing, reinforcing sleeve, and compressed air line are integrated in a single injection molding process, eliminating the need for manual assembly and fittings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coupling head is manufactured using traditional methods with separate metal housing and pre-assembled reinforcing sleeve, then the structural strength is sufficient, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines the housing and reinforcing sleeve into a single integrated component manufactured via injection molding. The housing is designed with an integrated reinforcing sleeve that is molded as one piece, eliminating the need for separate assembly steps and reducing part count. This merging of components directly addresses the contradiction by simplifying manufacturing while maintaining structural integrity.
Solution Approach 2:
The reinforcing sleeve is nested within the housing structure during the injection molding process. The sleeve is formed as an integral part of the housing, with the plastic material of the housing encapsulating the sleeve structure. This nesting approach allows the reinforcing sleeve to be embedded within the housing without requiring separate assembly operations.
2Productivity
If manual assembly with fittings is used to connect the compressed air line to the housing, then the connection is secure, but the production time and labor intensity increase
Solution Approach 1:
The connection between the compressed air line and housing is merged into a single integrated structure. The housing is injection molded with built-in connection features that directly receive and secure the compressed air line without requiring separate fittings or assembly steps. This eliminates manual assembly operations while maintaining secure connections through the integrated design.
Solution Approach 2:
The injection molding process itself creates the connection between the housing and compressed air line. The molding operation automatically forms the connection features and secures the air line in place during the molding process, eliminating the need for subsequent assembly operations. The structure serves its own connection function through the molding process.
3Ease of manufacture
If multiple separate components are used for the housing and reinforcing sleeve, then the structural integrity is maintained, but the manufacturing expense increases
Solution Approach 1:
The housing and reinforcing sleeve are merged into a single injection-molded component. The integrated design maintains structural integrity by forming the sleeve as an integral part of the housing, with the plastic material providing continuous structural support. This merging simplifies manufacturing while preserving the strength benefits of having both housing and reinforcement in one piece.
Solution Approach 2:
The patent uses plastic material with reinforcing elements to create a composite structure. The housing is made from plastic that incorporates reinforcing fibers or structures during injection molding, providing both the housing function and reinforcement function in a single material system. This composite approach maintains structural integrity while enabling single-step manufacturing.
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 significantly reduces manufacturing costs and time by creating a cohesive, inseparable structural unit that is both cost-effective and efficient to produce.
Implementation Method 1
a free end (16) of the compressed air line (10) is positioned in an injection molding tool (not shown here but easily imaginable) for injection molding the injection molding (14), preferably made of polyamide, consisting of the reinforcing sleeve (12) and the housing (2) including the mounting eye (20)
Implementation Method 2
In order to form a particularly good material connection between the compressed air line and the housing and reinforcing sleeve produced during the injection process, at least the free end of the compressed air line is preferably preheated before positioning in the injection molding tool.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a coupling head (1) for pneumatically connecting the braking system of a tractor and a trailer, wherein the coupling head comprises a housing (2) having at least one connection (6) for a flexible compressed air line (10), reinforced at least in the area of the connection (6) by at least one flexible reinforcement sleeve (12) at least partially tolerating displacements of the compressed air line (10). According to the invention, at least one part of the housing (2) of the coupling head (1) comprising the at least one connection (6) is implemented with the reinforcing sleeve (12) as an integral injection molded part (14) made from plastic, and a free end (16) of the compressed air line (10) is bonded to the injection molded part (14), protruding through the reinforcing sleeve (12) and into a connecting hole (12) of the connection (6).