Laser-Transparent Line Connector for Pipe-in-Pipe Systems
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Solution Overview
Problem
Existing line connectors for pipe-in-pipe systems face challenges in providing easy and cost-effective connections, especially when dealing with frost-prone media like urea-water solutions in SCR catalytic converter systems, where freezing issues and rigid outer pipes complicate access for welding, requiring special measures to prevent freezing and ensure functional connectivity at low temperatures.
Innovation Solution
A line connector design featuring integrally formed attachment parts and a connecting sleeve that allows for easy assembly and access to the connection point, enabling a welded connection between the inner pipe and the connector, even with rigid outer pipes, by using a laser-transparent material for the connecting element to facilitate reliable laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to produce a firmly bonded connection between the inner pipe and connecting elements, then a reliable connection is achieved, but free access to the connection area is required which is problematic when the outer pipe consists of rigid material
Solution Approach 1:
The line connector is divided into separate modular components: an attachment part for the inner pipe, a pipe adapter part for the outer pipe, and a connecting sleeve that joins them. This segmentation allows the inner pipe connection to be prepared independently before final assembly, enabling laser welding access while maintaining a compact final structure.
Solution Approach 2:
The inner pipe connection is prepared in advance by inserting the inner pipe into the attachment part and performing the laser welding connection between the inner pipe and inner connecting element before the final assembly with the pipe adapter and connecting sleeve. This preliminary action ensures reliable bonding while maintaining ease of assembly later.
2Strength
If the outer pipe consists of rigid material that cannot be compressed axially, then structural integrity is maintained, but easy assembly of the line connector is compromised
Solution Approach 1:
The connecting sleeve is designed with elastic material properties that allow it to be compressed axially during assembly to push the pipe adapter onto the rigid outer pipe, then it elastically recovers to maintain a firm connection. This dynamic behavior enables easy assembly while maintaining the structural integrity of the rigid outer pipe.
Solution Approach 2:
The connecting sleeve's axial compression parameter is utilized during assembly to enable the pipe adapter to be pushed onto the rigid outer pipe. The material's elastic properties allow temporary parameter change (compression) during assembly, followed by recovery to the original state for maintaining connection strength.
3Strength
If a firmly bonded connection is produced by laser welding, then connection strength is improved, but the design complexity and production cost increase
Solution Approach 1:
The connection structure is segmented into standardized components (attachment part, pipe adapter, connecting sleeve) that can be manufactured separately using cost-effective processes and assembled later. This reduces the complexity of producing each component while maintaining overall connection strength through laser welding of the inner pipe connection.
Solution Approach 2:
The connecting sleeve acts as an intermediary component that joins the attachment part and pipe adapter. It simplifies the overall assembly process and reduces design complexity by providing a standardized connection mechanism, while the actual strong bond is created through laser welding between the inner pipe and inner connecting element.
4Manufacturing precision
If the inner connecting element extends over the entire length of the space for welding access, then welding space is maximized, but the device complexity increases
Solution Approach 1:
The inner connecting element serves multiple functions: it provides the laser welding connection surface for the inner pipe, acts as a structural support, and extends to maximize the welding space. This multi-functionality allows a single component to achieve welding precision while avoiding the need for additional complex structures.
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 design ensures a simple, cost-effective, and reliable connection of media lines, maintaining functionality at low temperatures and preventing freezing issues, while allowing for efficient heat transmission and easy assembly, even with non-compressible outer pipes.
Implementation Method 1
the inner connecting element comprises a sleeve-like connecting piece for inserting the inner pipe and consists, at least partially of a laser-transparent material. As a result, an especially simple and reliable bond can be formed by means of laser welding between the inner pipe and inner connecting element.
Data Source
AI summary
A line connector with two mutually separate flow paths for the connection of a pipe-in-pipe line. The line connector has an inner connecting element for connecting to an inner pipe of the pipe-in-pipe line, an outer connecting element for connecting to an outer pipe of the pipe-in-pipe line, a first attachment element for attachment of the first line to the inner pipe, and a second attachment element for attachment of the second line to the outer pipe. The inner connecting element and the first attachment element are integrally formed on a separate attachment part. The outer connecting element is integrally formed on a separate pipe adapter part. And, the second attachment element is integrally formed on a separate connecting sleeve. The connecting sleeve permits at both sides, in the unassembled state, being pushed over the outer pipe. The invention also relates to a line set including the line connector.