Quick Disconnect Coupling With Additive-Made Interlocking Assembly
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Solution Overview
Problem
Existing quick connect/disconnect couplings for aerospace applications are complex and costly due to the large number of machined parts required, complicating assembly and increasing production costs.
Innovation Solution
The use of additive manufacturing to create simplified quick connect/disconnect couplings with reduced parts, featuring unique structural elements such as inclined threads and resilient interlocking elements, which reduce assembly time and complexity while maintaining performance standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional machining processes are used to create quick connect/disconnect couplings, then manufacturing precision and reliability are maintained, but device complexity and production costs increase due to the large number of parts required
Solution Approach 1:
The patent merges multiple traditionally separate components (valve body, seals, threading elements, locking mechanisms) into a single monolithic structure formed by additive manufacturing. This consolidation eliminates the need for assembling multiple machined parts while maintaining functional integrity and sealing performance through the integrated design.
Solution Approach 2:
The additively manufactured coupling member performs multiple functions simultaneously: it provides structural support, creates fluid sealing paths, incorporates threading for connection, and includes integrated locking features. This multi-functionality in a single part reduces overall device complexity while maintaining manufacturing precision through digital design control.
2Reliability
If multiple machined parts are assembled together to form the coupling, then reliable performance under high-pressure loads is achieved, but assembly time and production costs increase
Solution Approach 1:
By combining multiple functional elements into one additively manufactured component, the patent eliminates assembly steps required for traditional multi-part constructions. The single-piece design maintains reliability under high-pressure loads through optimized internal structures and integrated sealing paths that are inherently sealed by the manufacturing process itself.
3Force
If traditional coupling designs are used, then mechanical advantage for high-pressure loads is provided, but the number of components that must be machined and assembled increases
Solution Approach 1:
The patent integrates threading elements, locking mechanisms, and structural support features into a single additively manufactured component. This merging maintains the mechanical advantage needed for high-pressure loads while eliminating the need for multiple separate components that would traditionally be required to achieve the same force transmission and locking capabilities.
Data Source
AI summary
A coupling having a male nipple (12) and a female coupler (14), in which one or both of the coupling members provides a simplified construction with a reduced number of parts for minimizing assembly time and overall costs. The coupling member(s) may include unique interlocking elements (38, 49), such as flexible finger elements, that slidably secure the valve sleeve(s) to the valve bodies. The female coupler (14) may include a valve body (23) with a unique interface, such as interlocking teeth, for rotatably coupling to a thread sleeve (51). The thread sleeve (51) may have a bendable web for facilitating assembly of a spring for an actuating sleeve. The actuating sleeve may be formed with a hollow annular internal chamber. The male nipple (12) may include the actuating sleeve instead of the female coupler (14). Other features also may be optimized, such as via additive manufacturing techniques, including coupling threads, fluid orifices, biasing members, and seal members.