Modular Fluid Coupling Structure for Strong Low-Cost Line Crimping
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Solution Overview
Problem
Existing fluid couplings have complex designs that lead to high manufacturing costs and material demands, making them costly and inefficient.
Innovation Solution
A fluid coupling design that separates the core element for fluid guidance from shell elements for structural support, allowing for a reduced core element wall thickness and enabling the use of cost-effective materials for the shell elements, with press sleeves for secure fluid line connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the fluid coupling uses a seamless integration of fluid flow sections and crimping sections, then the connection strength is improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The fluid coupling is divided into separate functional sections: a core element for fluid flow and shell elements for crimping support. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining connection strength through the integrated assembly of these specialized parts.
Solution Approach 2:
The core element and shell elements are combined in an integrated assembly where the shell elements surround and support the core element. This merging of separate components creates a unified structure that provides both fluid flow capability and crimping support, resolving the contradiction between simplicity and strength.
2Productivity
If the core element wall thickness is reduced to improve fluid flow characteristics, then the fluid flow performance is improved, but the structural strength decreases
Solution Approach 1:
The coupling is segmented into a thin-walled core element for optimal fluid flow and separate shell elements for structural support. This allows the core element to have minimal wall thickness for improved flow characteristics while the shell elements provide the necessary structural strength independently.
Solution Approach 2:
The fluid coupling uses a composite structure combining the core element and shell elements, where each part is made from materials optimized for its specific function. The core element material is optimized for fluid flow, while the shell element material provides structural reinforcement, achieving both goals simultaneously.
3Reliability
If expensive materials are used to ensure connection reliability, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
Different materials are used for different parts of the coupling based on their specific functional requirements. The core element uses material optimized for fluid flow and sealing, while the shell elements use material optimized for crimping support and structural integrity. This local optimization ensures reliability without unnecessarily high costs throughout the entire component.
Solution Approach 2:
The fluid coupling employs a composite structure with different materials for the core element and shell elements, allowing each material to be selected for its optimal performance characteristics and cost-effectiveness for its specific function, rather than using a single expensive material throughout.
4Ease of manufacture
If a single integrated component design is used, then the manufacturing process is simplified, but the adaptability to different applications decreases
Solution Approach 1:
The fluid coupling is designed as segmented modular components (core element and interchangeable shell elements) that can be configured for different applications. Each shell element can be designed for specific connection requirements, allowing the same core element to be adapted to various applications by simply changing the shell elements, thus maintaining manufacturing simplicity while increasing versatility.
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 improves fluid flow characteristics and reduces costs while ensuring secure and leak-proof connections, using a modular approach with interchangeable shell elements and a rotational locking mechanism.
Implementation Method 1
the respective press sleeve is further configured to be plastically deformed radially inwards by a force acting radially outwards on the press sleeve
Data Source
Figure 1
Figure 2~3
AI summary
Fluid coupling (10) for connecting fluid lines, comprising a first fluid connection, a second fluid connection (18) and at least two shell elements (14), wherein the fluid connections (16, 18, 20) are integrally formed on a common core element (12), wherein the at least two shell elements (14) are configured to surround the core element (12) at least on each of the first and second fluid connections (16, 18) on its respective radial outer side, wherein the fluid coupling (10) further comprises a press sleeve for each fluid connection (16, 18, 20), which is configured to be received on a section (34) of the at least two shell elements (14) that radially surrounds a respective fluid connection (16, 18, 20), wherein the respective press sleeve is further configured to be plastically deformed radially inwards by a force acting radially outwards on the press sleeve.so that a corresponding fluid line is permanently connected to the respective associated fluid connection (16, 18, 20) without damage.