Overmolded Support Assembly With Anti-Rotation Fluid Coupling
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Solution Overview
Problem
Current support assemblies for mounting coupling components in fluid systems face challenges with durability and efficient mounting, often resulting in manufacture and performance issues.
Innovation Solution
A support assembly comprising a metal mounting bracket with an engagement surface defining a void, and a polymer coupling component with an intermediate portion that extends through and partially fills the void, providing a locking surface to prevent rotation and forming a fluid passage, along with an efficient method of overmolding the coupling component onto the mounting bracket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting bracket designs are used, then the support assembly can be manufactured, but it suffers from durability and performance issues
Solution Approach 1:
The patent combines the mounting bracket and coupling component into a single integrated support assembly. The mounting bracket includes an engagement surface with a void that receives and secures the coupling component, eliminating the need for separate mounting operations and improving both durability and manufacturing efficiency.
Solution Approach 2:
The support assembly utilizes different materials for different components: the mounting bracket is made of a first material while the coupling component is made of a second material. This composite material approach allows each component to be optimized for its specific function, improving overall reliability while maintaining ease of manufacture.
2Reliability
If the coupling component is securely mounted, then durability is improved, but rotation of the coupling component occurs without proper restraint
Solution Approach 1:
The engagement surface of the mounting bracket includes a void with an asymmetric cross-sectional profile that matches the asymmetric profile of the coupling component. This asymmetric geometry creates a locking mechanism where the coupling component fits securely without rotation, as the profiles are designed to interlock in a specific orientation only.
Solution Approach 2:
The coupling component is nested within the void of the mounting bracket, with the intermediate portion of the coupling component extending through and partially filling the void. This nesting arrangement provides both secure mounting and rotational restraint through the interlocking geometries.
3Ease of operation
If the coupling component is easily mounted, then ease of operation is improved, but manufacturing efficiency may be compromised
Solution Approach 1:
The mounting bracket and coupling component are designed as an integrated assembly where the coupling component is permanently secured within the void of the mounting bracket. This merging eliminates separate mounting steps during installation (improving ease of operation) while allowing for efficient overmolding manufacturing (improving productivity).
Solution Approach 2:
The mounting bracket is pre-formed with the void and engagement surface geometry that will receive the coupling component. This preliminary preparation allows for quick assembly and efficient manufacturing through the overmolding process, where the coupling component is molded directly onto the pre-prepared mounting bracket.
Data Source
AI summary
A support assembly comprises a mounting bracket and a coupling component. The mounting bracket comprises a first material and has an engagement surface defining a void along a first axis. The coupling component comprises a second material, which is different than the first material. The coupling component has a first end, a second end, and an intermediate portion. The intermediate portion extends through, and partially fills, the void defined by the mounting bracket. The intermediate portion defines a fluid passageway about the first axis within the void and also presents a locking surface. The locking surface abuts the engagement surface to prevent rotation of the coupling component with respect to the mounting bracket.