Integrated Refrigerant Container Forming via Die Reduction
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Solution Overview
Problem
The existing methods for manufacturing containers for absorbing fluid or mechanical shock, such as those used in refrigerant systems, require multiple welding processes and additional coupling pipes, leading to increased manufacturing costs, weight, noise generation, and reduced refrigerant flow due to thickness differences and pressure variations.
Innovation Solution
A method that integrates a container body and a coupling pipe into a single structure by using a die to form the container body and coupling pipe from a raw material pipe, reducing the outer diameter and forming the inner circumference, eliminating the need for additional welding and simplifying the coupling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate coupling pipes are welded to the container body, then the container can be assembled and connected to refrigerant feeding means, but manufacturing costs increase due to multiple welding processes and washing operations
Solution Approach 1:
The coupling pipe and container body are merged into a single integrated structure formed from a single pipe through the die forming process. This eliminates the need for separate welding operations to attach coupling pipes to the container body, directly reducing manufacturing costs and simplifying the assembly process while maintaining the required connectivity functions.
2Productivity
If the diameter of the pipe is reduced through the forming process, then the container body and coupling pipe can be formed, but a difference in pipe thickness occurs reducing refrigerant flow
Solution Approach 1:
The die is designed with different forming zones: a first forming zone that reduces the diameter to form the container body, and a second forming zone that maintains the original diameter to form the coupling pipe. This local differentiation ensures that the coupling pipe section retains sufficient thickness for optimal refrigerant flow while the container body section achieves the required reduced diameter for structural integrity.
3Ease of operation
If multiple welding processes are used to join coupling pipes, then the container can be assembled, but noise is generated due to pressure differences
Solution Approach 1:
The coupling pipe and container body are formed as a single integrated structure through die forming, eliminating the welding joints that create noise. The integrated structure ensures uniform wall thickness and seamless transitions, preventing the pressure differences and vibrations that cause noise in welded assemblies.
4Adaptability or versatility
If separate coupling pipes are used, then the container can be connected to refrigerant feeding means, but the external appearance is affected by thickness differences at junctions
Solution Approach 1:
The coupling pipe and container body are merged into a single continuously formed structure, eliminating the visible junction and thickness differences that mar the external appearance. The die forming process creates a seamless transition between the container body and coupling pipe sections, providing a uniform and smooth external surface while maintaining full connection capability to refrigerant feeding means.
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 reduces manufacturing and material costs, minimizes noise and refrigerant flow issues, and provides a smoother, more uniform external appearance by eliminating the need for separate coupling pipes and welding, while enhancing the structural integrity and efficiency of the container.
Implementation Method 1
reducing the outer diameter and forming an inner circumference of the coupling pipe
Implementation Method 2
an inner-circumference cutting process
Data Source
AI summary
Disclosed herein is a method of manufacturing a container for absorbing fluid shock or mechanical shock. The method includes preparing a raw material pipe, forming a coupling pipe by reducing a diameter of at least one side of the raw material pipe, and forming an inner circumference of the coupling pipe and bending it. Accordingly, a container body and a coupling pipe coupled to at least one side of the container body are integrated together, so that an additional process for coupling the container body with the coupling pipe is not required, and thus the cost of production is reduced.