Modular Connector Ultrasonic Welding Reduces Mold Complexity
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Solution Overview
Problem
The complexity of push-in fittings for fluidic pipes, with numerous variants of tubular bodies and connection devices, leads to high manufacturing costs and inefficiencies due to the need for multiple molds and small production series for uncommon variants.
Innovation Solution
A modular connector system with standardized connecting devices and tubular bodies, where the connecting devices have identical dimensions and adaptable ends, and tubular bodies with standardized sockets, allowing for a wide range of combinations with fewer parts, secured by annular ultrasonic welds, and featuring a radially orientable base and visual cues for correct positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of variants of tubular bodies and connection devices is increased to meet diverse connection needs, then the adaptability and versatility of the fitting range is improved, but the device complexity and manufacturing cost increase due to the need for multiple molds
Solution Approach 1:
The connector is divided into two separable parts: a tubular body and a connection device. Each can be manufactured independently using standard molds, then assembled through ultrasonic welding. This segmentation allows the same tubular body to work with multiple connection device variants, reducing the total number of molds needed while maintaining diverse fitting options.
Solution Approach 2:
The standardized tubular body design with universal socket interface can accommodate multiple types of connection devices (castellated socket, push-in tail, snap-in tail). This universal interface approach allows one tubular body mold to support multiple connection configurations, reducing overall complexity.
2Adaptability or versatility
If the number of fitting variants is increased to provide comprehensive connection solutions, then the adaptability is improved, but the manufacturing efficiency deteriorates due to small production series for uncommon variants
Solution Approach 1:
By separating the tubular body from the connection device, each component can be manufactured in larger batches using standardized molds. The tubular bodies can be produced in high-volume series, and connection devices can be manufactured separately, both achieving economies of scale that would be impossible if every variant required a complete custom mold set.
Solution Approach 2:
The invention recovers the value of standardized components across multiple variants. Instead of creating entirely new fittings for each application, the same tubular body design is reused and adapted to different connection needs through interchangeable connection devices, maximizing the utilization of each mold investment.
3Manufacturing precision
If traditional molding methods are used for each fitting variant, then the manufacturing precision is maintained, but the production cost increases due to the large number of required molds
Solution Approach 1:
The connector is segmented into tubular body and connection device components manufactured separately using precision molding, then joined by ultrasonic welding. This approach maintains the high precision benefits of molding for each component while avoiding the need to mold complete assembled variants, significantly reducing the number of expensive custom molds required.
Solution Approach 2:
The invention replaces the traditional mechanical assembly (screwing, clipping) with ultrasonic welding to join the tubular body and connection device. This substitution maintains connection strength and precision while enabling more efficient manufacturing and reducing the complexity of mold designs needed for each variant.
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 modular system significantly reduces the number of molds required, lowers production costs, and facilitates the creation of a broader range of fittings by allowing for the development of new combinations with fewer components, while ensuring secure and leak-proof connections.
Implementation Method 1
The surfaces of revolution are secured by an annular ultrasonic weld
Data Source
Figure 1~6
Figure 7~12
Figure 13~14
AI summary
The connection (29) has a connection device (9) that is made of thermoplastic material, and comprising a tubular portion (11). An end (13) of the tubular portion is connected to a conduit i.e. tube, to allow passage of fluid between the conduit and the tubular portion. A flange (5) is arranged with a rotary tubular connection surface (7) such as external surface. The connection device is provided with a set of forms including a notched form (17), a plug-in tail form, and a retainable tail form, and a connection unit of the connection device is provided with an identical dimension. An independent claim is also included for a method for manufacturing a modular connection.