Modular Polyamide Air Distributor Block for Pneumatic Systems
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Solution Overview
Problem
Existing air distributors in utility vehicle pneumatic systems are heavy, complex, prone to corrosion, and require additional protection, leading to inefficiencies in weight, space usage, and potential air leaks due to multiple connections.
Innovation Solution
A modular air distributor block made of polyamide with at least 30% glass fibre, comprising interconnected modules with integrated seals and connectors, reducing the need for additional protection and minimizing connections, allowing for customizable configurations and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If monolithic aluminium alloy distributors are used, then structural strength is ensured, but weight is excessive and corrosion resistance is poor
Solution Approach 1:
The distributor is divided into multiple separate modules (first module, second module, third module) that can be assembled together. Each module contains specific functional elements like sockets and connectors, allowing the system to achieve the required structural strength through the assembly of multiple components rather than requiring a single heavy monolithic structure.
Solution Approach 2:
The patent uses aluminium alloy for the structural modules to ensure strength while keeping weight optimized. The combination of aluminium alloy modules with plastic connectors and rubber seals creates a composite system that achieves both mechanical strength and weight reduction compared to traditional monolithic metal distributors.
2Adaptability or versatility
If multiple brass joints are mounted in sockets, then connectivity is achieved, but seal quality deteriorates and air leaks occur
Solution Approach 1:
The patent removes the brass joint component entirely from the system. Instead of using traditional brass joints mounted in sockets, the invention uses integrated plastic connectors with embedded threading that directly engage with pneumatic conduits, eliminating the intermediate brass joint that caused sealing problems and air leaks.
Solution Approach 2:
The connector elements are merged directly into the module structures. The plastic connectors are integrally formed with the modules and include embedded threading, combining the functions of the module body, socket, and connector into a single integrated component that ensures reliable sealing without requiring separate brass joints.
3Duration of action of stationary object
If metal alloy distributors are used, then durability is achieved, but additional protective coatings are required against corrosion
Solution Approach 1:
The patent uses aluminium alloy for the structural modules which naturally forms a protective oxide layer, providing corrosion resistance without requiring additional protective coatings. The plastic connectors and rubber seals are inherently corrosion-resistant, creating a composite system that achieves durability without the complexity of applying and maintaining protective coatings on metal surfaces.
4Adaptability or versatility
If traditional distributors are used, then functionality is provided, but space occupation is excessive
Solution Approach 1:
The distributor system is segmented into compact modular units that can be closely assembled together. The first module, second module, and third module are designed with optimized dimensions and can be mounted in a compact arrangement, significantly reducing the overall space occupation compared to traditional monolithic distributors while maintaining full pneumatic system functionality.
Solution Approach 2:
The modular design allows the distributor system to be arranged in a three-dimensional compact configuration. The modules can be stacked or arranged vertically and horizontally to optimize space utilization, transitioning from a traditional horizontal expansion to a multi-dimensional compact arrangement that reduces the footprint in the vehicle.
5Adaptability or versatility
If modular design with multiple connections is used, then configurability is improved, but assembly complexity increases
Solution Approach 1:
The patent employs standardized mounting holes and fastening elements that are consistent across all modules. The first module, second module, and third module all use the same types of mounting holes, fastening elements, and connection interfaces, allowing for easy assembly and reconfiguration. This universal interface design enables customizable configurations while keeping assembly complexity low through standardization.
Data Source
AI summary
An air distributor block in pneumatic systems of utility vehicles has at least two modules with a body joined together, at least one mounting hole, at least one through-hole, at least one fastening element and seals placed between the modules is characterized by the fact that it comprises two outer modules: the upper module and the lower module equipped with a central coaxial blind hole with the identical hole in the other modules, and each outer module has at least two mounting through-holes parallel to the central axis of the module, in which bolts are mounted, which protrude above the outer modules, terminated on each side with a threaded tip for connecting to the vehicle frame, where in two opposite side walls of each outer module sockets are made with embedded connector elements or sockets equipped with blinding plugs.