Laser-Welded Corrugated Plastic Hose Joint With Stop Positioning

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Solution Overview

Problem

Existing liquid lines with corrugated plastic hoses face challenges in achieving reliable and efficient connections due to high production costs, complex logistics, and long cycle times, particularly for small diameters, where process reliability and quality control are compromised.

Innovation Solution

A liquid line design featuring a laser-welded connection piece made from laser-transparent plastic, with a calibrated corrugated hose end for a press fit and a stop profile for precise positioning, allowing for simplified assembly and reduced errors, using a guide element to stabilize the hose and ensure hydraulic sealing without additional measurement tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a laser-transparent plastic connection piece is used for laser welding, then welding speed and productivity are improved, but manufacturing precision and assembly reliability deteriorate due to positioning difficulties

Engineering Contradiction:

Improvewelding speedVSAvoidpositioning precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The corrugated hose is pre-calibrated at its end region before assembly, creating a standardized interface that fits precisely into the connection piece. This preliminary preparation ensures accurate positioning during laser welding without requiring complex positioning tools or procedures during the actual welding process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A calibration element or stop profile is introduced as an intermediary component between the corrugated hose and the connection piece. This intermediary feature provides a precise mechanical reference that guides the hose into the correct position, ensuring repeatable and accurate alignment during laser welding operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If multiple separate components (O-ring, securing ring) are used for connection, then sealing reliability is improved, but device complexity and production costs increase

Engineering Contradiction:

Improvesealing reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connection piece integrates multiple functions into a single component: it provides both the sealing surface (replacing the O-ring function) and the securing mechanism (replacing the securing ring function). The laser welding process creates both the seal and the mechanical connection simultaneously, eliminating the need for separate sealing and securing components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection piece is designed as a multi-functional component that performs sealing, mechanical attachment, and positioning functions all in one element. This universal component works with the laser welding process to achieve both hydraulic sealing and structural connection without requiring additional specialized parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If manual measurement and positioning tools are used during assembly, then manufacturing precision is improved, but productivity and cycle time deteriorate

Engineering Contradiction:

Improveassembly precisionVSAvoidassembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The calibration element or stop profile on the corrugated hose provides self-positioning functionality during assembly. The hose automatically finds its correct position through the mechanical interface with the connection piece, eliminating the need for external measurement tools or skilled operators to perform positioning operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mechanical calibration features and stop profiles replace the need for measurement tools and manual positioning procedures. The precision is achieved through built-in mechanical reference features rather than through measurement and adjustment processes, significantly speeding up assembly while maintaining high precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 design enhances process reliability and quality assurance by reducing assembly errors, simplifying the welding process, and lowering production costs, while ensuring a secure and air-gap-free connection, thus improving the efficiency and precision of the liquid line assembly.

Implementation Method 1

the corrugated hose is introduced into the tubular portion and is welded to the latter all round from radially at the outside by way of a laser beam

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS11788657B2Liquid line with a plastic corrugated hose

Publication Date: 2023.10.17 CONTINENTAL AUTOMOTIVE TECHNOLOGIES GMBH

AI summary

A liquid line improved in terms of effective producibility with a high level of process reliability and quality assurance comprising at least one corrugated hose and at least one connection piece for connecting the liquid line to a further component, wherein the corrugated hose and the connection piece are produced from plastic and are connected to one another via at least one welded connection, wherein the welded connection is produced by means of a laser welding process, wherein the welded connection is tight at least up to a defined operating pressure in the liquid line and wherein a stop is formed in the connection piece and defines an axial end position of the corrugated hose in the connection piece.