Quick Coupling Assembly With Unitary 3D-Printed Valve Structure
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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 coupling members with reduced parts, forming components such as valve bodies, sealing sleeves, and actuating sleeves as unitary structures, which reduces the number of machined parts and assembly complexity, while maintaining or exceeding industry standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional machining methods are used to create coupling members, then manufacturing precision and reliability are improved, but device complexity and production costs increase due to the large number of parts required
Solution Approach 1:
Multiple discrete machined parts (valve body, sealing sleeve, actuating sleeve, spring, thread sleeve) are merged into a single unitary structure formed by additive manufacturing. The female coupler and male nipple are each created as one integrated component, eliminating the need for assembly of multiple parts while maintaining all necessary functional features including flow passages, sealing surfaces, and actuating mechanisms
Solution Approach 2:
The unitary coupling member structure performs multiple functions simultaneously: it provides fluid flow pathways, sealing surfaces, actuating mechanisms, and structural support all within a single component. The additive manufacturing process enables integration of features that would traditionally require separate parts, making each coupling member a multi-functional universal component
2Reliability
If multiple machined parts are assembled together, then functional requirements are met, but assembly time and manufacturing costs increase
Solution Approach 1:
The coupling member is manufactured as a single unitary structure through additive manufacturing, eliminating the assembly process entirely. Features such as the valve body, sealing sleeve, actuating sleeve, spring, and thread sleeve are integrated into one component, reducing assembly time to zero for these elements while maintaining all required coupling functions and performance characteristics
3Manufacturing precision
If traditional machining processes are used, then manufacturing precision is achieved, but production costs and inventory requirements increase
Solution Approach 1:
The manufacturing process is changed from traditional subtractive machining to additive manufacturing, fundamentally altering how the coupling members are created. This parameter change enables production of complex geometries in a single process step, reducing the number of machining operations, tooling requirements, and assembly steps, thereby lowering production costs while maintaining manufacturing precision through controlled deposition and curing processes
Data Source
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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.