Blow-Molded Polymer Tube Arrangement With Integrated Flow Control
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Solution Overview
Problem
Existing tube arrangements for temperature control in electric vehicles and air conditioning systems are complex, costly, and difficult to recycle due to their multi-material construction and complex assembly requirements, which complicates their production and installation in limited spaces.
Innovation Solution
A tube arrangement produced by blow molding using a polymeric base body with integrated functional elements, such as throttle valves and sensors, that are directly embedded within the base body, allowing for a compact, customizable, and cost-effective design that simplifies assembly and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tube arrangements use multi-material construction (metal pipes, thermoplastic sections, rubber-like sections) to optimize performance for different conditions, then functional adaptability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple functional elements (throttle valves, check valves, sensors, connectors) and different material sections into a single integrated base body made of polymeric material. This consolidation eliminates the need for separate metal pipes, thermoplastic sections, and rubber-like sections, reducing assembly complexity while maintaining all required functions through the unified polymeric structure
Solution Approach 2:
The polymeric base body serves multiple functions simultaneously: it acts as the structural housing, contains integrated throttle valves for flow control, incorporates check valves for directional flow, embeds sensors for monitoring, and provides connector interfaces. This multi-functionality within a single component replaces the need for multiple specialized components made from different materials
2Adaptability or versatility
If tube arrangements use multi-material construction with separate components, then functional optimization for specific conditions is improved, but ease of manufacture deteriorates due to complex assembly requirements
Solution Approach 1:
The patent combines all functional elements into a single monolithic base body produced by injection molding. The throttle valves, check valves, sensors, and connectors are all integrated into this one component, eliminating the need for separate assembly steps and reducing manufacturing complexity while maintaining functional optimization for different operating conditions
3Adaptability or versatility
If tube arrangements use complex multi-component structures, then functional capability is improved, but productivity deteriorates due to time-consuming assembly processes
Solution Approach 1:
The patent merges all functional components into a single base body that can be produced in one injection molding cycle. This eliminates time-consuming assembly operations for connecting separate metal pipes, thermoplastic sections, and rubber-like sections, significantly improving productivity while maintaining full functional capability through the integrated polymeric structure
4Manufacturing precision
If tube arrangements use separately formed functional elements, then functional precision is improved, but device complexity increases due to multiple assembly steps
Solution Approach 1:
The patent merges all functional elements into the base body through injection molding, where throttle valves, check valves, sensors, and connectors are formed as integral parts of the polymeric structure. This eliminates assembly steps while maintaining manufacturing precision through the molding process, which can produce complex geometries with high accuracy in a single operation
Data Source
AI summary
A tube arrangement for the transport of temperature control medium, comprising a base body (2) made of polymeric material and produced by means of blow molding, wherein at least one functional element (3) is arranged in the base body (2), which element is in operative connection with the temperature control medium.