ISO Flare Union Assembly for Leak-Free Brake Tube Connections
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Solution Overview
Problem
Existing fluid-to-fluid line connection systems face challenges in achieving a secure and leak-free connection between tubes, particularly in brake line systems, where traditional flared connections may not provide reliable seals and can be prone to misalignment and high torque requirements.
Innovation Solution
A female ISO flare union with an integrated mating brake ISO F flare port is designed, featuring a female body with a press-formed inward flare and a mating flare nut, which securely engages the flared ends of the tubes through a clinching operation, ensuring a fluid-tight connection and reduced torque requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional flared connections are used, then tube connection is achieved, but reliable seal and leak-free connection cannot be ensured
Solution Approach 1:
The patent combines the tube connection function and the sealing function into a single integrated flare nut assembly. The flare nut simultaneously clamps the tubes together and creates the seal through its integrated sealing surface, eliminating the need for separate sealing components and ensuring reliable leak-free connection.
Solution Approach 2:
The patent introduces a sealing element as an intermediary component between the flare nut and tubes. This sealing element fills the interface gap and provides the actual sealing action, mediating between the mechanical connection and the fluid barrier function.
2Ease of operation
If traditional flared connections are used, then tube connection is achieved, but misalignment during assembly occurs
Solution Approach 1:
The patent incorporates alignment features and tolerance compensation mechanisms in advance of the assembly process. The flare nut design includes built-in alignment guides and compliant elements that compensate for misalignment, cushioning the assembly process against precision requirements and enabling easier installation.
3Strength
If traditional flared connections are used, then tube connection is achieved, but high torque requirements are needed
Solution Approach 1:
The patent replaces the traditional high-torque mechanical threading system with a clamp-style connection mechanism. This substitution uses distributed clamping force through the integrated flare nut rather than relying on high torque to create friction-based holding force, reducing the required assembly torque while maintaining connection strength.
Solution Approach 2:
The patent employs curved or angled contact surfaces in the flare nut design that distribute forces more evenly. The geometry of the sealing surface and clamping interface is optimized to convert axial clamping force into radial sealing pressure, improving mechanical efficiency and reducing the torque needed to achieve the required connection strength.
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
The solution provides a reliable, leak-free connection with lower torque needs, reduced misalignment during assembly, and improved stability in brake line systems, enabling efficient vehicle sub-assembly without the use of long, easily bent tubes, while also offering ergonomic assembly and weight savings.
Implementation Method 1
A press operation forms an inward flare to the first open end of the female body to capture the mating port and the first tube end form
Data Source
AI summary
A brake union for providing a secure and leak free connection between first and second fluid carrying lines inserted into a female union body having a first and second open ends. Each of the fluid carrying lines exhibits an expanded, typically flared, end form which, upon inserting through the female body, seat against one another. A mating flare nut coaxially surrounds one of the fluid carrying lines and includes exterior threads which inter-engage interior threads of the female body, with tightening to establish a fluid-tight connection between the opposing end forms.