Pipe Connection Point Molding for Secure Branch Line Routing
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Solution Overview
Problem
Existing pipeline manufacturing methods in automotive engineering, particularly for temperature control systems, face challenges such as limited installation space, risk of injury, and reduced durability due to loose secondary lines and arbitrary attachment of cable ties or hose clamps, which lead to damage and inefficiencies in assembly and maintenance.
Innovation Solution
The method involves forming connection points in the pipeline sections using mold blocks that run centrally through the connection points, creating a 90° offset to the flow cross-section, allowing for monolithic integration with the pipeline wall, enabling standardized sections and pre-assembled guide elements like clips for secure and space-efficient assembly, reducing the risk of injury and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cable ties or hose clamps are used to attach branch lines to pipelines, then the branch lines can be secured and located easily, but the installation space increases, the pipeline wall is weakened by radial compression, and the risk of injury from sharp edges increases
Solution Approach 1:
The connection point is integrated directly into the pipeline wall as a monolithic molded part, combining the pipeline structure with the attachment feature. This eliminates the need for separate cable ties or hose clamps, reducing installation space and component complexity while maintaining secure attachment capability
Solution Approach 2:
The connection point is pre-formed during pipeline manufacturing with the wall structure, creating standardized attachment locations before installation. This eliminates the need for arbitrary on-site attachment decisions and reduces installation complexity
2Ease of operation
If cable ties are used to secure branch lines, then the branch lines are easy to locate, but the cable ties are difficult to remove, are damaged during disassembly creating waste, and leave protruding sections that create sharp edges increasing injury risk
Solution Approach 1:
The invention replaces disposable cable ties with a permanent, reusable connection point integrated into the pipeline. The connection point can be used repeatedly without damage, eliminating waste and safety hazards associated with disposable fasteners
Solution Approach 2:
The connection point structure includes integrated features that guide and secure branch lines without requiring external fastening components. The design serves its own fastening function through the molded-in structure
3Ease of operation
If hose clamps or cable ties are used as attachment points, then branch lines can be secured, but considerable installation space is required and the pipe wall is weakened by radial compression leading to potential breaks or leaks
Solution Approach 1:
The connection point is formed as an integral part of the pipeline wall structure, merging the attachment function with the pipeline structure itself. This eliminates radial compression from external fasteners and preserves wall integrity
Solution Approach 2:
The connection point creates a localized reinforcement area in the pipeline wall where the attachment is needed, without affecting the overall wall strength. The molded structure distributes loads locally rather than compressing the wall radially
4Ease of manufacture
If pipelines are manufactured as continuous tubes with homogeneous structure, then the manufacturing process is simple and consistent, but the installation space is limited and auxiliary lines complicate assembly and maintenance
Solution Approach 1:
Connection points are pre-formed during the pipeline manufacturing process, preparing attachment locations in advance. This maintains manufacturing simplicity while enabling efficient later assembly of branch lines without complicating the basic extrusion process
Solution Approach 2:
The pipeline is provided with discrete, standardized connection points at specific locations, segmenting the otherwise continuous homogeneous structure. This enables organized attachment of auxiliary lines while maintaining the simplicity of continuous manufacturing
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a method for producing a pipeline (2), wherein the pipeline (2) is formed in a corrugator and encloses a free flow cross-section (Q) for a fluid with a wall (4), by forming two forming jaws (26) enclosing a pipeline section (6) and opening in opposite opening directions (O) from a parting plane X and thereby demolding the pipeline (2), wherein a connection point (8) is formed in at least one pipeline section (6) by the parting plane (X) of the forming jaws (26) running centrally through the connection point (8).