Pump Housing Thermal Joining Without Screws or Adhesives

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Solution Overview

Problem

Existing pump device manufacturing methods are costly, heavy, and environmentally unfriendly due to the use of separate connecting components like screws and adhesives.

Innovation Solution

A method where a metal housing of a pump device is combined with a component having a plastic outer side, connected through a thermal joint formed by melting the plastic with heat supply, eliminating the need for additional connecting components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate connecting components (screws, adhesives) are used to connect the component to the metal housing, then the mechanical connection is reliable, but the manufacturing cost increases and the weight increases

Engineering Contradiction:

Improvemechanical connection reliabilityVSAvoidnumber of connecting components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the component and metal housing into a single integrated structure through thermal joining. The component is heated to melt its outer layer, allowing direct fusion with the metal housing without requiring separate connecting components like screws or adhesives. This eliminates multiple parts while maintaining connection reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical connection systems (screws, bolts, adhesives) with a thermal joining process. By heating the component to melt its outer layer and fuse it with the metal housing, the invention substitutes mechanical assembly methods with a thermal bonding process, reducing part count and simplifying the overall structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If separate connecting components (screws, adhesives) are used to connect the component to the metal housing, then the connection is stable, but the weight of the pump device increases

Engineering Contradiction:

Improveconnection stabilityVSAvoidweight of pump device

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines the component and housing into a unified structure through thermal fusion, eliminating the need for additional connecting components that would add weight. The melted outer layer of the component fuses directly with the metal housing, creating a bonded joint without extra fasteners or adhesives.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If separate connecting components (especially adhesives) are used, then the connection is achieved, but the environmental impact increases and manufacturing becomes less sustainable

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces chemical bonding methods (adhesives) with a thermal joining process. By heating the component to melt its outer layer and fuse it with the metal housing, the invention eliminates the need for chemical adhesives, reducing harmful emissions and environmental impact while simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If the plastic outer side of the component is melted to form a thermal joint, then the number of connecting components is reduced and weight is reduced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvenumber of connecting componentsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent utilizes the phase transition of the component's outer layer from solid to liquid state through heating. This melting process allows the material to flow and fuse with the metal housing, creating a strong thermal joint. The phase change enables bonding without requiring complex assembly mechanisms.

Inventive Principle:

Principle #36Phase transitions

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 approach reduces manufacturing costs, weight, and environmental impact by simplifying the production process and enhancing the mechanical stability and load-bearing capacity of the pump device.

Implementation Method 1

the plastic of the component is melted at the connecting section and wets the connecting section

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

By heating the metal housing, in particular inductively, the plastic of the component is melted at the connecting section

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20250135731A1Method for producing a pump device

Publication Date: 2025.05.01 MAHLE INT GMBH

AI summary

A method of manufacturing a pump device for conveying a fluid may include providing a metal housing and a further component. The further component may have plastic on at least one outer side. The method may further include bringing the at least one outer side of the further component into contact with a connecting section of the metal housing, heating the metal housing such that the plastic of the further component melts at the connecting section of the metal housing and wets the connecting section, and terminating the heating of the metal housing such that the plastic hardens and the further component is thermally joined to the metal housing at the connecting section.