Sacrificial Connecting Block for Corrosion Protection

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Solution Overview

Problem

Existing one-piece connecting blocks for fluid transfer are expensive to produce due to complex geometry requirements and suffer from corrosion issues that create leak paths and restrict fluid connection joints.

Innovation Solution

A connecting block design comprising two members, where a sacrificial second member is slidably received within a first member, with a bonding zone created by heating both parts to form a physical connection, protecting the sealing surface from corrosion and allowing for cost-effective production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If one-piece connecting blocks are entirely machined from a single piece of material, then the complex geometry requirements are met, but the production cost becomes expensive

Engineering Contradiction:

Improvecomplex geometryVSAvoidproduction cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The connecting block is divided into two separate members: a first member containing flow headers and a second member with flow member receiving bores. This segmentation allows each member to be manufactured using simpler, more cost-effective processes while maintaining the overall complex geometry through assembly of the components.

Inventive Principle:

Principle #1Segmentation

2Reliability

If one-piece connecting blocks are made from corrosion resistant material, then corrosion resistance is improved, but corrosion at male extending members or female tubing receiving bores still creates leak paths

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidcorrosion at connection points

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The second member is made from a sacrificial material that is less corrosion-resistant than the first member. This sacrificial component is designed to corrode preferentially, protecting the critical sealing surfaces and flow headers on the first member from corrosion, thereby preventing leak paths at the connection points.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If two members are used with sacrificial material, then corrosion protection at sealing surfaces is improved, but the device complexity increases

Engineering Contradiction:

Improvecorrosion protectionVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The second member is slidably received within the first member, with the smaller second member nested inside the larger first member. This nesting arrangement minimizes the increase in device complexity while enabling the sacrificial corrosion protection mechanism. The members are then bonded together through heating to create a permanent physical connection.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 design reduces production costs and minimizes corrosion at sealing surfaces, enhancing the integrity of fluid joints by using a sacrificial material for the second member to protect the first member, thus improving the reliability of fluid connections.

Implementation Method 1

A material of the second member is corrosively sacrificial with respect to a material of the first member

Methodology Applied

Scientific EffectGalvanic corrosion: Crevice Corrosion

Implementation Method 2

A bonding zone is created by heating both the first and second members until the planar end face and the planar interior face join together to create a physical connection

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

A bonding zone is created by heating both the first and second members until the planar end face and the planar interior face join together

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8833803B2Connecting block

Publication Date: 2014.09.16 DENSO INTERNATIONAL AMERICA INC

AI summary

A connecting block includes a first member having a flow header extending from a sealing surface, a planar end face oppositely directed with respect to the sealing surface, and a perimeter wall angularly oriented with respect to the sealing surface. A second member is slidably received within the perimeter wall of the first member and has a flow member receiving bore axially aligned with the flow header. A bonding zone is created by heating both the first and second members until the planar end face and the planar interior face join together to create a physical connection between the first and second members. A material of the second member is corrosively sacrificial with respect to a material of the first member.