Laser-Welded Hose Connection for Stress-Free Sanitary Fittings
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Solution Overview
Problem
Existing connection methods for sanitary installations, such as crimping and molding, impose mechanical stress and are complex, particularly when connecting rigid and flexible components like fittings and hoses, which is problematic in the sanitary sector.
Innovation Solution
A material-bonded connection, preferably through laser welding, ultrasonic welding, or thermal welding, is established between the connection part and the hose, using the same type of plastic for both components, often with reinforcing additives, ensuring a stable and permanent bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If crimping is used to connect the hose and connection part, then the connection is mechanically stable, but mechanical stress is imposed on the fitting which reduces reliability
Solution Approach 1:
The patent replaces the mechanical crimping connection system with a material-bonded connection system using welding (laser, ultrasonic, or thermal welding). This substitution eliminates the mechanical stress imposed on the fitting by crimping while maintaining connection stability, as the welding process creates a permanent bond between the hose and connection part without deforming the fitting.
Solution Approach 2:
The patent changes the connection method from mechanical (crimping) to material-bonded (welding), fundamentally altering the connection parameters. The welding process uses thermal energy to melt and fuse the thermoplastic materials, creating a strong bond that does not impose mechanical stress on the fitting, thereby resolving the contradiction between connection stability and fitting reliability.
2Reliability
If molding is used to connect the hose and connection part, then the connection is permanent, but the manufacturing process becomes complex
Solution Approach 1:
The patent segments the manufacturing process into distinct steps: first inserting the hose into the connection part, then applying welding energy to create the material-bonded connection. This segmentation simplifies the overall manufacturing process compared to molding, as it avoids complex multi-step molding operations while achieving permanent connection through a straightforward insert-and-weld sequence.
Solution Approach 2:
The patent replaces the complex molding process with a simpler welding process. Instead of using molds to shape and connect the components, the invention uses welding energy (laser, ultrasonic, or thermal) to directly bond the thermoplastic hose and connection part, significantly reducing manufacturing complexity while maintaining permanent connection.
3Productivity
If traditional connection methods are used, then the manufacturing process is simple, but the connection cannot withstand high flow rates
Solution Approach 1:
The patent uses composite material bonding through welding of thermoplastic components. The material-bonded connection creates a unified structure between the hose and connection part that can withstand high flow rates, while the welding process itself maintains manufacturing efficiency. The thermoplastic materials are selected to be weldable, ensuring both connection strength and manufacturing simplicity.
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 method provides a mechanically stable and reliable connection that is resistant to high flow rates, allowing for improved functionality and operational characteristics of sanitary installations.
Implementation Method 1
the material-bonded connection is created by welding, preferably by laser welding
Implementation Method 2
the material-bonded connection is created by welding, preferably by laser welding, ultrasonic welding
Implementation Method 3
the material-bonded connection is created by welding, preferably by laser welding, ultrasonic welding or thermal welding
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a sanitary installation arrangement (1) comprising a connection part (2) and a hose (3), it is proposed that the connection part (2) has a hose receptacle (4) which overlaps with the hose (3) in a connection direction, and that there is a material-bonded connection (5) between the connection part (2) and the hose (3).