Thermal Junction Box Assembly With Sliding Sleeves for Leak-Tight Flow
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Solution Overview
Problem
Existing thermal junction boxes for concrete core temperature control are costly, difficult to handle and assemble, prone to leaks due to O-ring damage and contamination, and restrict hydraulic flow, limiting their flexibility and efficiency.
Innovation Solution
A thermal junction box constructed from lightweight, inexpensive modules using sliding sleeve connections and ball valves, eliminating O-rings and reducing pressure losses, allowing connection to various pipe diameters and enabling easy assembly and high tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a solid brass body is used to deflect volume flow and accommodate connection components, then connection functionality is achieved, but weight increases making handling and assembly difficult
Solution Approach 1:
The solid brass body is segmented into separate functional components: a lightweight housing structure and individual connection elements that can be assembled together. This segmentation reduces the overall weight while maintaining the deflection and connection functionalities through distributed components rather than a single heavy monolithic structure.
Solution Approach 2:
The patent replaces expensive, heavy brass components with lighter, more cost-effective materials that can be easily manufactured and assembled. The connection components are designed as separate, replaceable elements rather than integral parts of a heavy brass body, reducing both weight and material costs.
2Adaptability or versatility
If a solid brass body is used to deflect volume flow and accommodate connection components, then connection functionality is achieved, but manufacturing costs increase
Solution Approach 1:
Segmenting the brass body into separate components allows each part to be manufactured independently using optimized processes for that specific component, reducing overall manufacturing complexity and cost compared to machining a single complex brass assembly.
Solution Approach 2:
The patent substitutes expensive brass material with more economical materials that are easier and cheaper to manufacture, while maintaining the required functional performance for volume flow deflection and connection accommodation.
3Ease of operation
If plug-in couplings with spring-loaded rubber bodies are used, then quick connection is achieved, but hydraulic cross-section is restricted leading to low volume flows and high pressure losses
Solution Approach 1:
The patent removes the spring-loaded rubber body sealing mechanism from the plug-in coupling, replacing it with a sealing solution that does not encroach on the hydraulic cross-section. This eliminates the flow restriction caused by the rubber seal while maintaining the quick connection functionality.
Solution Approach 2:
The patent replaces the flow-restricting rubber seal with a sealing mechanism that maintains full hydraulic openness, allowing maximum volume flow without the pressure losses associated with restricted cross-sections.
4Ease of operation
If plug-in couplings are used for room-side connections, then easy assembly is achieved, but contamination risk increases leading to leaks
Solution Approach 1:
The patent extracts and eliminates the vulnerable plug-in coupling mechanism with its contamination-prone internal chambers and sealing surfaces. The replacement design allows for contamination-resistant assembly while maintaining ease of installation.
Solution Approach 2:
The patent replaces the contamination-susceptible plug-in coupling with a connection design that is inherently more resistant to dirt and contaminants, reducing the risk of leakage from contamination while preserving quick assembly capabilities.
5Reliability
If steel braided or armored hoses are used with plug-in couplings, then connection durability is improved, but costs increase
Solution Approach 1:
The patent replaces the expensive steel braided or armored hoses with more cost-effective piping solutions that achieve comparable or sufficient durability for the application, reducing material costs while maintaining connection reliability.
Solution Approach 2:
The patent adopts a universal connection approach that works with standard piping materials rather than requiring specialized armored hoses, making the system more adaptable and cost-effective while maintaining adequate durability through proper connection design.
Data Source
Figure 1
Figure 2~3
AI summary
The box (1) has a housing (2), and supply and discharge pipes (3, 7) provided for heat transfer medium. Deflection devices (4, 8) are connected with the pipes, respectively. Spherical valves (5, 9) are connected with the deflection devices. The deflection devices are fastened to a base of the housing, where connections between the supply and discharge pipes and the deflection devices takes place by axial press connection with sliding sleeves (6, 10), respectively. The sleeves sealingly close openings required for guiding the supply and discharge pipes through a housing wall.