Pipe Coupling Structure Using Plastic Deformation to Cut Cost
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Solution Overview
Problem
The manufacturing cost of pipe coupling members is high due to material waste and complex cutting processes, and replacing damaged components requires replacing the entire member, increasing overall costs.
Innovation Solution
A pipe coupling member with a coupling body supported by a cylindrical support member, allowing the locking element latching surface to be formed by plastic deformation, reducing material waste and enabling a thin-walled structure, and incorporating a valve element and spring for fluid control without additional spring-supporting portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the coupling body is manufactured by cutting process, then sufficient rigidity and structural integrity are achieved, but material waste increases and manufacturing cost increases
Solution Approach 1:
The invention changes the manufacturing method from cutting to plastic deformation, fundamentally altering the processing parameter. The coupling body is formed by plastically deforming a metal blank using a stamping die, which eliminates material removal and associated waste while maintaining structural integrity through controlled deformation.
Solution Approach 2:
The invention employs a thin-walled coupling body structure that is formed through plastic deformation. The thin-walled design reduces material consumption while the plastic deformation process ensures the wall thickness and structural strength are sufficient to withstand operational loads without requiring excessive material.
2Strength
If the coupling body is manufactured by cutting process, then a single member with sufficient rigidity is obtained, but the number of cutting steps increases and manufacturing complexity increases
Solution Approach 1:
The invention transitions from multiple cutting operations to a single plastic deformation process. The coupling body with its complex geometry including the locking element latching surface is formed in one stamping operation, eliminating the need for multiple cutting steps and associated setup, tooling, and processing time.
Solution Approach 2:
The invention performs preliminary forming of the coupling body shape and the locking element latching surface simultaneously during the plastic deformation process. The metal blank is pre-shaped into the final coupling body configuration with all necessary features integrated, eliminating subsequent machining or forming operations.
3Strength
If the coupling body is made as a single member, then structural integrity is maintained, but replacement of damaged components requires replacing the whole member
Solution Approach 1:
The invention divides the pipe coupling member into separable components: the coupling body, valve element, seal member, and spring. The coupling body serves as the structural housing that can remain in place, while internal components like the valve element and seal member can be independently accessed and replaced through the open end of the coupling body, facilitating maintenance without replacing the entire assembly.
4Loss of substance
If plastic deformation process is used, then material waste is reduced and manufacturing cost is reduced, but the coupling body must be thin-walled
Solution Approach 1:
The invention optimizes the plastic deformation parameters including blank thickness, deformation force, and die geometry to produce a thin-walled coupling body with sufficient strength. The controlled plastic deformation allows precise control over wall thickness distribution, ensuring adequate strength while minimizing material usage.
Solution Approach 2:
The invention successfully implements a thin-walled coupling body structure that is formed through plastic deformation. The thin-walled design is made feasible by the inherent strength-to-weight ratio achieved through the deformation process and appropriate material selection, allowing reduced material consumption while maintaining functional requirements.
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 solution reduces manufacturing costs by minimizing material waste and simplifying the manufacturing process, while allowing for easy replacement of individual components, thus lowering the overall cost of the pipe coupling member.
Implementation Method 1
a deformed portion deformed radially inward between the forward end and the rear end to form a locking element latching surface
Data Source
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AI summary
[Technical Problem] To provide a pipe coupling member capable of reducing the manufacturing cost as compared to conventional pipe coupling members. [Solution to Problem] A pipe coupling member 101 includes a coupling body 110 defining a part of a fluid passage 120, and a support member 116 disposed inside the coupling body 110. A valve accommodating space 130 is defined inside the coupling body 110 at a position forward of the support member 116, and a valve element 118 is disposed in the valve accommodating space 130 to open and close the fluid passage 120. The coupling body 110 is formed from a thin-walled pipe material and has a deformed recess 126 formed by plastically deforming radially inward a portion of the coupling body 110 that covers an annular groove 122 of the support member 116. The deformed recess 126 has a locking element latching surface 128 along a support surface 122a of the annular groove 122. When the pipe coupling member 101 is connected to an associated pipe coupling member, the locking element latching surface 128 is latched by a locking element of the associated pipe coupling member, thereby allowing the pipe coupling member 101 to be held by the associated pipe coupling member.