Line Connector Assembly with Thermal Insulation
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Solution Overview
Problem
Lines used in high-temperature applications, such as engines, face material stress leading to embrittlement, leakage, and reduced service life due to thermal expansion and temperature resistance limitations, necessitating the use of expensive, high-temperature-resistant plastics to prevent damage and contamination.
Innovation Solution
An assembly with a connector and an intermediate element that provides thermal insulation and sealing, allowing the line to be made from cost-effective materials, as the intermediate element absorbs temperature stress and compensates for dimensional differences between the line and connector, using materials like rubber-like compounds or silicones with high temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cost-effective plastics are used for the line, then manufacturing cost is reduced, but the line becomes embrittled and decomposed due to high operating temperatures
Solution Approach 1:
The system is divided into three segments: the line (made from cost-effective plastic), the intermediate element (made from heat-resistant material), and the connector (exposed to high temperature). This segmentation allows each component to be optimized independently, with the line using inexpensive material while the intermediate element protects it from thermal damage.
Solution Approach 2:
The intermediate element acts as a mediator between the line and the connector. It thermally insulates the line from the high-temperature connector, preventing heat transfer to the plastic line while still allowing mechanical connection and fluid passage.
2Reliability
If high-temperature-resistant plastics are used for the line, then service life is extended, but manufacturing cost increases
Solution Approach 1:
Heat resistance is applied locally only where needed - in the intermediate element that contacts the hot connector - rather than requiring the entire line to be made from expensive heat-resistant plastic. This localized application of special material properties reduces overall cost while maintaining reliability.
3Adaptability or versatility
If the line is made flexible to compensate for movements, then adaptability is improved, but temperature resistance decreases
Solution Approach 1:
The system separates the flexibility function (performed by the plastic line) from the heat resistance function (performed by the intermediate element). This allows the line to remain flexible for adaptability while the intermediate element provides the necessary thermal protection.
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 extends the service life of the line by preventing material decomposition from high temperature stress, ensuring a secure and leak-proof connection, and reducing operational costs by using inexpensive materials while maintaining functionality under vibrations and movements.
Implementation Method 1
The direct contact of the intermediate element with the conductor and the intercalation of the intermediate element ensure a thermal insulation of the line from the connector
Implementation Method 2
The lines are under heavy stress due to the different operating temperatures. Areas of the lines have different coefficients of thermal expansion
Data Source
AI summary
An assembly for connecting a line includes a connector for detachable connection of a line, a line that can be connected to the connector, and an intermediate element for connection to the connector and the line. The intermediate element is secured on the line in such a manner that it separates the line and the connector from one another.