Sheet Metal Connector Socket With Integral Collar for Leak-Safe Cooling
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Solution Overview
Problem
Existing connector systems for liquid flows, such as those used in cooling systems, require burdensome and error-prone welding or brazing processes to secure spigots to sheet metal containers, leading to potential leaks and structural weaknesses.
Innovation Solution
A connector assembly featuring a sheet metal collar structure formed integrally with the container using sheet metal forming processes, combined with a ring-shaped snap-on module for tool-free assembly and enhanced sealing with O-rings, providing a robust and reliable connection without the need for additional manufacturing steps like welding or brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or brazing is used to attach the socket to the sheet metal wall, then the mechanical connection strength is improved, but the manufacturing complexity and potential for errors increase
Solution Approach 1:
The socket is integrally formed with the sheet metal wall through sheet metal forming processes, merging two previously separate components (socket and wall) into a single integrated structure. This eliminates the need for welding or brazing while maintaining mechanical strength, as the socket becomes an inherent part of the wall structure itself.
Solution Approach 2:
The connector socket is designed with a distinct protruding collar structure that segments the connection function from the wall structure. The collar protrudes from the sheet metal plate and provides a dedicated interface for receiving the spigot, separating the sealing and connection functions from the structural wall components.
2Stability of the object's composition
If welding or brazing is used to create the connection, then structural integrity is improved, but the risk of leaks and impurities increases
Solution Approach 1:
By integrally forming the socket with the sheet metal wall, the invention eliminates the weld or brazing joint that could create impurities or leakage paths. The integrated structure ensures continuous material flow without discontinuities, preventing harmful factors associated with thermal joining processes.
Solution Approach 2:
The invention replaces expensive and potentially defective welding/brazing processes with a simpler, more reliable sheet metal forming process. The forming process creates a inherently leak-free structure without requiring additional sealing materials or complex joint designs.
3Strength
If a traditional socket with welding is used, then the connection robustness is improved, but the ease of assembly deteriorates
Solution Approach 1:
The connector means is segmented into a collar structure integrally formed with the wall and a separate connector component that receives the spigot. This segmentation allows the robust connection to be achieved through mechanical interlocking rather than permanent joining, enabling easy assembly and disassembly while maintaining strength.
Solution Approach 2:
The connector means acts as an intermediary component between the sheet metal wall and the spigot. It provides a mechanical interface that enables tool-free assembly through snap-fit or similar mechanisms, while the integral collar structure ensures robust connection without requiring welding or specialized tools.
4Strength
If multiple manufacturing steps including brazing or welding are used, then the connection strength is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The socket and wall are merged into a single integrated component formed in one sheet metal forming operation. This eliminates multiple sequential manufacturing steps (forming separate socket, then welding/brazing it to the wall) and replaces them with a single forming process, significantly improving manufacturing efficiency while maintaining connection strength.
Solution Approach 2:
The collar structure is preliminarily formed as an integral part of the sheet metal plate during the initial forming process. This preliminary action creates the connection interface in advance, eliminating the need for subsequent welding or brazing operations and streamlining the overall manufacturing process.
Data Source
AI summary
The invention relates to a connector socket for connecting a spigot (12) to an orifice (10a), said connector socket including a sheet metal plate (10) with said orifice (10a) and a protruding collar structure (16) surrounding said or-ifice (10a). 10 It is proposed that the collar structure (16) is integrally made of the sheet metal of said sheet metal plate (10) by a sheet metal forming process.