Plug-Type Coupling Pre-Assembly Locking for Leak-Safe Connection
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Solution Overview
Problem
Existing plug-type couplings face limitations in usability due to large locking lug dimensions, which restrict the use of circumferential seals, and are prone to leakage and detachment under high pressures and temperatures, especially for mating plug connectors with diameters greater than 14 mm, and require increased assembly effort.
Innovation Solution
The design incorporates a positive-locking element that expands radially when the plug shaft is inserted, blocking the locking element from moving into a locking position unless the mating plug connector is fully inserted, and features a three-part seal for enhanced sealing, reducing the risk of detachment and improving assembly control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If locking lugs are made large to provide positive locking, then locking reliability is improved, but the device complexity and assembly space requirements increase
Solution Approach 1:
The locking mechanism is divided into multiple independent locking lugs (at least two) distributed around the circumference of the adapter sleeve. Each locking lug independently engages with a corresponding locking recess in the sleeve section, distributing the locking function across multiple smaller elements rather than relying on a single large locking structure.
Solution Approach 2:
The locking lugs are designed with specific local geometries including inclined locking surfaces that provide automatic engagement and positive locking. The locking lugs have optimized local dimensions and shapes that enable reliable locking without requiring large overall dimensions, with each lug tailored to its specific engagement point.
2Reliability
If locking lugs are made large to ensure positive locking, then locking reliability is improved, but the ability to arrange circumferential seals is restricted
Solution Approach 1:
The locking mechanism uses multiple segmented locking lugs spaced around the circumference rather than a single large locking structure. This segmentation creates gaps between the locking lugs that allow circumferential seals to be arranged in the radial direction, enabling both reliable locking and effective sealing.
Solution Approach 2:
The locking lugs are arranged in the circumferential direction around the adapter sleeve, creating a radial pattern that leaves space in the radial dimension for seal placement. This dimensional arrangement allows the sealing function to coexist with the locking function without interference.
3Reliability
If the locking element can move freely into locking position, then connection security is improved, but assembly effort increases due to premature locking
Solution Approach 1:
The adapter sleeve is pre-assembled into the receiving channel and the locking lugs are pre-positioned on the adapter sleeve before the actual connection operation. This preliminary assembly ensures that when the plug shaft is inserted, the locking mechanism is already in position to engage automatically without requiring additional assembly steps.
Solution Approach 2:
The locking element is designed to be movable in the axial direction, allowing it to dynamically transition between a retracted position during insertion and a locked position upon full engagement. This dynamic behavior enables automatic locking that occurs naturally during the assembly process without requiring increased assembly effort.
4Reliability
If the retaining means is always locked, then detachment prevention is improved, but insertion control is worsened
Solution Approach 1:
The locking element is designed as a movable component that can dynamically switch between a retracted state during insertion and a locked state after proper engagement. This dynamic design allows the system to provide insertion control during assembly while maintaining detachment prevention after connection is complete.
Solution Approach 2:
The locking mechanism provides feedback through the movable locking element that indicates whether the plug connector is properly inserted. When insertion is incomplete, the locking element remains retracted, providing feedback that prevents premature locking. Once proper insertion is achieved, the locking element automatically transitions to the locked position, confirming secure connection.
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
This solution reduces assembly effort, enhances sealing reliability, and prevents unintended detachment of the mating plug connector, even under high pressures and temperatures, by ensuring proper insertion and maintaining a secure connection.
Implementation Method 1
The retaining means protrudes into the through-opening in a resting state and is designed to be expandable radially in relation to the assembly axis when in a tensioned state
Implementation Method 2
a positive-locking element that expands radially when the plug shaft is inserted, blocking the locking element from moving into a locking position
Data Source
AI summary
A plug-type coupling for connecting first and second fluid lines or a sub-assembly, which are designed with a mating plug-type coupling. The plug-type coupling including a housing including a sleeve section with a receiving channel (8) for axially receiving an adapter sleeve. The adapter sleeve being removably held in a positive-locking manner. The adapter sleeve includes a through-opening for a plug shaft of the mating plug-type coupling and a retaining means for removable attachment of the mating plug-type coupling. In an assembled state, the retaining means axially blocks the mating plug-type coupling with respect to the assembly axis. A locking element is arranged on an outer circumference of the sleeve section and is axially movable from a release position, which releases the retaining means, into a locking position, which locks the retaining means. In the release position, the locking element is fixed against axial movement into the locking position.