Plastic Pipe Connector with Fillets to Reduce Flow Losses
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Solution Overview
Problem
Existing pipe connectors, especially those made of gunmetal and plastic, face challenges such as high production complexity and significant fluid flow losses due to complex manufacturing processes and design limitations, particularly in heating and cooling systems.
Innovation Solution
A plastic pipe connector designed with two housing parts that are injection molded and joined using gluing or welding, featuring a ramp and fillets in the crossing area to optimize fluid flow, allowing for complex structures and reduced vortex formation, thus minimizing flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pipe connectors are made of gunmetal using casting process, then production complexity is reduced, but production cost increases and manufacturing complexity remains high due to copper content
Solution Approach 1:
The pipe connector is divided into two separate housing parts (first housing part and second housing part) that are injection molded independently and then joined together. This segmentation allows each part to be manufactured separately using simple injection molding processes, avoiding the complexity of casting while enabling complex internal structures with flow optimization features like ramps and fillets.
Solution Approach 2:
The invention changes the material from gunmetal to plastic and the manufacturing process from casting to injection molding. This parameter change simplifies the manufacturing process while allowing for complex geometries and flow optimization features that would be difficult or impossible to achieve with casting.
2Ease of manufacture
If pipe connectors are made of plastic with angles or branches, then production cost decreases, but flow losses increase significantly
Solution Approach 1:
The invention introduces rounded corners (fillets) in critical flow areas instead of sharp angles. This curvature reduces flow separation and vortex formation, minimizing energy losses while maintaining the complex branched structure. The rounded transitions guide fluid flow smoothly through corners and junctions.
Solution Approach 2:
The invention applies flow optimization features (ramps and fillets) specifically in critical areas where flow losses would occur, such as corner areas and crossing sections. The rest of the structure maintains standard plastic injection molding simplicity. This localized application of flow optimization reduces energy losses without significantly increasing manufacturing complexity.
3Ease of manufacture
If housing is produced in one piece by injection molding, then manufacturing is simple, but demolding becomes problematic for complex structures
Solution Approach 1:
The housing is divided into two separable parts (first housing part and second housing part) that can be injection molded independently using simple molds without slides. After molding, the parts are joined together to form the complete complex structure. This segmentation allows each part to be manufactured with simple injection molding while the assembled structure achieves the required complexity.
4Adaptability or versatility
If complex structures are created in plastic housing, then design flexibility increases, but flow resistance increases due to vortex formation in corner areas
Solution Approach 1:
The invention introduces rounded corners (fillets) in critical flow areas instead of sharp angles. This curvature reduces flow separation and vortex formation, minimizing energy losses while maintaining the complex branched structure. The rounded transitions guide fluid flow smoothly through corners and junctions.
Solution Approach 2:
The invention applies flow optimization features (ramps and fillets) specifically in critical areas where flow losses would occur, such as corner areas and crossing sections. The rest of the structure maintains standard plastic injection molding simplicity. This localized application of flow optimization reduces energy losses without significantly increasing manufacturing complexity.
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 provides a cost-effective, flow-optimized pipe connector that reduces fluid resistance and allows for complex structures, enhancing the installation in tight spaces without significant cross-sectional changes, ensuring smooth fluid flow and easy integration in domestic installations.
Implementation Method 1
the at least one further pipe has a ramp in the crossing area which is suitable for directing a fluid flowing through the at least one further pipe over the pipe segment of the first pipeline
Implementation Method 2
a rounded corner being provided in the at least one corner area. As a result of this rounding, the formation of vortices in the laminar flow in the at least one pipeline can be reduced and the flow behavior of the fluid within this pipeline can thus be further optimized
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
The tube connector has a housing (2) and a pipeline (4) passed-through with a fluid, where the housing is made of plastic. The terminals (6,8) are provided at the ends of the pipeline for the connection with other pipelines. The housing portion (18) has a lower pipeline section of the former pipeline. Another housing portion (20) has an upper pipeline section of the former pipeline. The lower pipeline section has a corner area, in which a fillet is provided.