Push-In Connector Assembly Using Induction-Fused Metal Insert
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Solution Overview
Problem
Existing connector designs for connecting liquid and gaseous media require complex and costly manufacturing processes, particularly due to the formation of receiving grooves for sealing elements, and often necessitate additional components that overlap and complicate assembly.
Innovation Solution
A method involving a tubular connector body made of plastic with an insert element of ferromagnetic material, which is heated using an electromagnetic field to penetrate and embed into the plastic, forming a receiving groove for a sealing element, allowing for cost-effective and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a receiving groove for a sealing element is formed using conventional methods (as described in DE 10 2008 046 143 A1), then the groove can be completely formed by the connector body material, but the manufacturing cost becomes high
Solution Approach 1:
The receiving groove is divided into two parts: a first groove side surface and groove base surface formed by the connector body, and a second groove side surface formed by an insert element. This segmentation allows each part to be optimized independently - the insert element can be precisely manufactured and then inserted into the connector body, reducing overall manufacturing cost while maintaining groove formation quality
Solution Approach 2:
An insert element is introduced as an intermediary component between the connector body and the sealing element. This insert element forms part of the receiving groove (specifically the second groove side surface) and can be precisely manufactured separately, then inserted into the connector body to complete the groove formation, thereby reducing manufacturing cost while maintaining precision
2Ease of operation
If an additional holding element is arranged within the receiving sleeve (as described in EP 3 584 489 A1), then the sealing element can be retained and positioned, but the receiving sleeve must overlap both the connector body and the retaining element, complicating the assembly
Solution Approach 1:
The holding element is merged with the insert element, combining the functions of groove formation and sealing element retention into a single component. This eliminates the need for a separate receiving sleeve that would otherwise be required to hold the retaining element, thereby simplifying the overall assembly structure while maintaining ease of operation
Solution Approach 2:
The insert element is designed to perform multiple functions: it forms the second groove side surface of the receiving groove and simultaneously serves as the holding element for the sealing element. This multi-functionality eliminates the need for separate components, reducing assembly complexity while maintaining ease of operation
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
Enables quick and economical formation of receiving grooves with precise positioning and retention of the insert element, reducing manufacturing costs and simplifying the assembly process.
Implementation Method 1
the insert element itself or at least those holding sections protruding from the insert element is or are heated by the energy generated by an electromagnetic field by means of an inducing device to a temperature at least above the softening temperature of the plastic material of the connector body
Implementation Method 2
the insert element itself or at least those holding sections protruding from the insert element is or are heated by the energy generated by an electromagnetic field by means of an inducing device
Implementation Method 3
the plastic material is converted into a formable aggregate state at least in a direct contact area with the insert element itself or at least in a direct contact area with the holding sections protruding from the insert element
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a method and to a push-in connector (1) for connecting ducts for liquid and/or gaseous media. A push-in connector body (4), an insert element (15, 15-1, 15-2) and a sealing element (9) are provided. A first groove side face (11) and a groove bottom face (13) of a receiving groove (10) are formed in the push-in connector body (4) made of a plastic material. The insert element (15, 15-1, 15-2) forms a second groove side face (12) and is made of a metal material with ferromagnetic properties. The insert element (15-1) per se or a plurality of holding portions (24) projecting from the insert element (15-2) is/are each applied against an insert element holding portion (16) by way of a radial force oriented toward the side averted from the longitudinal axis (6) and is/are heated by means of an induction apparatus (18) at least to above the softening temperature of the plastic material of the push-in connector body (4). The insert element (15-1) per se or the holding portions (24) projecting from the insert element (15-2) penetrate/s into the moldable plastic material and are embedded in said plastic material in some regions.