Stamped Plug-In Sleeve Assembly for Low-Cost Tube Coupling
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Solution Overview
Problem
The production and assembly of existing plug-in inserts for coupling tubular elements to main bodies are complex and costly, requiring machining and assembly of individual parts.
Innovation Solution
A plug-in insert design featuring a plug-in sleeve formed by stamping and bending metallic flat material into a shell-shaped element, with a fixing element interlockingly fixed within, and a release member that cooperates with the fixing element for axial movement to release the tubular element, reducing production complexity and costs through a material-saving process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the plug-in sleeve is produced by machining individual parts, then the manufacturing precision and structural integrity are improved, but the production complexity and costs increase significantly
Solution Approach 1:
The patent merges multiple machining operations and assembly steps into a single stamping and bending process. The plug-in sleeve is formed from a single blank piece of material through sequential stamping and bending operations, eliminating the need to machine and assemble multiple separate components. This integration of processes directly reduces production complexity while maintaining manufacturing precision through controlled forming operations.
Solution Approach 2:
The patent changes the manufacturing parameters from subtractive machining to formative stamping and bending processes. By transitioning from removing material through machining to shaping material through controlled deformation, the process achieves the desired geometric precision with simpler equipment and fewer assembly steps, thereby reducing production complexity while preserving manufacturing quality.
2Strength
If the plug-in sleeve is produced by machining, then the structural strength and durability are improved, but the production time and costs increase
Solution Approach 1:
The patent performs preliminary forming operations during the stamping process itself, creating the final geometric shape and structural features of the plug-in sleeve before assembly. The bending operations pre-form the sleeve into its final configuration with integrated features, eliminating the need for subsequent machining operations and reducing overall production time while maintaining structural integrity through controlled material deformation.
Solution Approach 2:
The patent replaces traditional mechanical machining systems with stamping and bending forming systems. This substitution uses controlled plastic deformation mechanisms instead of cutting and removal processes, enabling faster production cycles while maintaining or improving structural strength through work hardening effects inherent in the forming process.
3Ease of repair
If multiple individual parts are assembled to form the plug-in insert, then the ease of repair and replacement are improved, but the assembly effort and production costs increase
Solution Approach 1:
The patent designs the plug-in sleeve with multi-functional features integrated into the single formed component. The same stamping and bending process creates both the structural body and the coupling features, eliminating the need for separate assembly operations. This universal forming approach reduces assembly effort while the modular nature of the formed sleeve maintains ease of repair and replacement at the component level.
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
The solution significantly reduces production effort and costs by using a stamping and bending process for the plug-in sleeve, enabling efficient and cost-effective manufacturing of the plug-in insert while maintaining reliable coupling and release functionality.
Implementation Method 1
The wall element is formed by stamping and bending a metallic flat material portion into a shell-shaped or circumferentially closed element
Data Source
AI summary
A plug-in insert configured for insertion into a main body is provided. The plug-in insert configured to releasably couple a tubular element to the main body and including a plug-in sleeve, a fixing element, and a release member. The fixing element can releasably fix a tubular element inserted via an insertion opening in the plug-in sleeve, and the release member cooperating with the fixing element to release the tubular element by an axial movement of the release member relative to the plug-in sleeve. The plug-in sleeve can include a sleeve portion formed of at least one wall element, the wall element being formed by stamping and bending a metallic flat material portion into a shell-shaped or circumferentially closed element, and the fixing element being enclosed by the sleeve portion and fixed in the sleeve portion in an interlocking manner.