Pipe Connecting Element With Transition Step for Void-Free Soldering
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Solution Overview
Problem
In air-conditioning systems, particularly those using CO2 as coolant, existing connecting elements face issues with mechanical resilience due to air pockets formed by conically cut pipe ends, leading to reduced tightness and potential coolant loss.
Innovation Solution
A connecting element design featuring a transition step between the through channel and receiving bore, accommodating protruding pipe sections and ensuring a uniform solder fill, along with a solder pocket for excess solder absorption, enhances mechanical resilience and tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pipe ends are cut conically due to production process, then pipe insertion is facilitated, but air pockets form during soldering leading to reduced mechanical resilience and tightness
Solution Approach 1:
The transition step is pre-formed in the connecting element before pipe insertion. This preliminary structural feature anticipates the conical pipe end geometry and provides a predetermined accommodation zone that guides the pipe end into proper positioning, ensuring the pipe bottom contacts the receiving bore bottom over the circumference while preventing air pocket formation during subsequent soldering operations
Solution Approach 2:
The transition step acts as an intermediary structure between the through channel and receiving bore. It serves as a mediating zone that accommodates the conical pipe end geometry, transferring the pipe from the through channel region to the receiving bore region while maintaining proper alignment and preventing harmful air pockets during the soldering process
2Ease of operation
If pipe ends are inserted directly into receiving bore, then assembly is simple, but gaps occur leading to air pockets and reduced mechanical resilience
Solution Approach 1:
The transition step is pre-formed in the connecting element before pipe insertion. This preliminary structural feature anticipates the conical pipe end geometry and provides a predetermined accommodation zone that guides the pipe end into proper positioning, ensuring the pipe bottom contacts the receiving bore bottom over the circumference while preventing air pocket formation during subsequent soldering operations
Solution Approach 2:
The transition step creates a localized structural variation within the connecting element. This local geometric feature is specifically designed to accommodate conical pipe ends while maintaining the overall simplicity of the connecting element design, providing enhanced gap control and solder distribution only where needed at the transition zone
3Manufacturing precision
If transition step is introduced to accommodate protruding pipe sections, then uniform solder fill is achieved, but device complexity increases
Solution Approach 1:
The receiving bore is segmented into distinct zones: the through channel region, the transition step region, and the receiving bore region. This segmentation allows each zone to perform its specific function - the transition step specifically accommodates protruding pipe sections and controls solder distribution, achieving uniform solder fill without requiring complex additional components
4Productivity
If pipe ends are cut conically, then production efficiency is maintained, but gaps lead to air pockets causing coolant loss in continuous operation
Solution Approach 1:
The transition step is pre-formed in the connecting element before pipe insertion. This preliminary structural feature anticipates the conical pipe end geometry and provides a predetermined accommodation zone that guides the pipe end into proper positioning, ensuring the pipe bottom contacts the receiving bore bottom over the circumference while preventing air pocket formation during subsequent soldering operations
Solution Approach 2:
The transition step converts the potentially harmful conical pipe end geometry (which causes gaps and air pockets) into a beneficial feature. By providing a dedicated accommodation zone for the conical shape, the transition step ensures proper pipe positioning and eliminates air pockets, transforming what was previously a production limitation into an advantage that maintains both production efficiency and connection reliability
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
The design ensures a stable, mechanically resilient connection with minimal gaps, maintaining high pressure resistance and coolant retention, suitable for high-pressure CO2 systems and other applications like fuel lines.
Implementation Method 1
the solder can fill the gap between the connecting element and the pipe essentially without voids
Data Source
AI summary
A connecting element for a pipe arrangement, comprising a base body with at least one through channel, a receiving bore for receiving a pipe end of a pipe, wherein the receiving bore corresponds with the through channel, wherein the receiving bore has a larger cross section than the through channel, wherein a transition step is introduced into the base body between the through channel and the receiving bore, and an arrangement and a method for manufacturing an arrangement.