Pipe Assembly Blow Molding With Cutting-Edge Functional Integration
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Solution Overview
Problem
Existing methods struggle to efficiently integrate complex-shaped functional elements, such as angled or curved connection components, into pipe assemblies used in electric vehicles due to difficulties in removing protruding material during the blow molding process.
Innovation Solution
A method involving a tool carrier with cutting edges is used to guide the blow molding process, allowing complex-shaped functional elements to be integrated into the pipe assembly, with the cutting edges creating a separation region during or after blow molding to facilitate the removal of protruding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex-shaped functional elements (angled or curved connection components) are integrated into the pipe assembly using conventional blow molding, then the functionality and versatility of the pipe assembly is improved, but the difficulty of removing protruding material increases significantly
Solution Approach 1:
The separation region is pre-formed in the mold cavity during the blow molding process itself, before the functional elements are fully integrated. This preliminary action ensures that the protruding material can be easily removed after molding without requiring complex post-processing operations, thus resolving the contradiction between integrating complex functional elements and ease of manufacturing.
Solution Approach 2:
A tool carrier with cutting edges is introduced as an intermediary element between the mold cavity and the functional elements. This tool carrier facilitates the separation of protruding material by creating a defined separation region, making the removal process straightforward even for complex-shaped functional elements, thereby resolving the manufacturing difficulty.
2Reliability
If functional elements are firmly integrated into the pipe assembly during blow molding, then the reliability and media-tightness of the connection is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The manufacturing process is segmented into distinct phases: forming the separation region in the mold cavity, integrating functional elements during blow molding, and subsequent easy removal of protruding material. This segmentation allows each phase to be optimized independently, maintaining reliable connections while simplifying the overall process through clear separation of operations.
Solution Approach 2:
The mold cavity itself performs the dual function of both forming the pipe assembly and creating the separation region for protruding material removal. This self-service approach eliminates the need for additional complex tooling or post-processing equipment, thereby maintaining manufacturing simplicity while ensuring reliable integration of functional elements.
3Adaptability or versatility
If protruding material is removed after blow molding is completed, then the flexibility in handling complex-shaped functional elements is improved, but the productivity of the manufacturing process decreases
Solution Approach 1:
The separation region is pre-formed in the mold cavity during the blow molding process itself, before the functional elements are fully integrated. This preliminary action ensures that the protruding material can be easily removed after molding without requiring complex post-processing operations, thus resolving the contradiction between integrating complex functional elements and ease of manufacturing.
Solution Approach 2:
The cutting edges on the tool carrier rapidly separate the protruding material from the pipe assembly in a single swift action immediately after blow molding. This rushing through of the separation operation minimizes the time added to the manufacturing cycle, maintaining high productivity while enabling flexible handling of complex-shaped functional elements.
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
Enables the easy integration and removal of complex-shaped functional elements, ensuring a compact and media-tight connection within the pipe assembly, enhancing the functionality and efficiency of temperature control systems in electric vehicles.
Implementation Method 1
a tubular preform is introduced into the blow mold and is put over the tool carrier with the functional element, the blow mold is closed and the pipe assembly is produced from the preform by blow molding
Implementation Method 2
the tool carrier is equipped with at least one cutting edge, wherein the blow molding tools bear against the at least one cutting edge when the blow mold is closed and press off the preform so that a separation region is formed
Data Source
AI summary
A method for producing a pipe assembly which has a base body with at least one channel, wherein at least one functional element is allocated to the channel. The functional element is arranged on a tool carrier, the tool carrier is inserted between blow molding tools of a blow mold, a tubular preform is introduced into the blow mold and is put over the tool carrier with the functional element, the blow mold is closed and the pipe assembly is produced from the preform by blow molding. The functional element is connected to the pipe assembly in a materially bonded and/or form-fitting manner, and the tool carrier is equipped with at least one cutting edge, wherein the blow molding tools bear against the at least one cutting edge when the blow mold is closed and press off the preform so that a separation region is formed.