Thermoplastic Cable Assembly for Pressurized Fluid Systems
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Solution Overview
Problem
Existing line arrangements for connecting a transmission to an oil cooler are complex, heavy, and costly due to multiple components, non-positive connections, and high assembly expenses, with weight being a significant disadvantage due to vibrations during driving.
Innovation Solution
A line arrangement using thermoplastic materials connected by friction welding, eliminating the need for additional securing means and reducing weight by integrating fluid lines and connecting parts in a materially bonded manner, with optimized fastening and alignment for improved assembly efficiency and resistance to temperature and pressure loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal lines and complex cast metal connection arrangements are used, then strength and pressure resistance are improved, but weight and device complexity increase
Solution Approach 1:
The patent changes the material parameter from metal to thermoplastic plastic, enabling the fluid lines to withstand pressure loads of up to 10 bar and temperature loads of 130°C while reducing weight by more than 50% compared to metal constructions
Solution Approach 2:
The patent uses composite thermoplastic constructions combining different plastic materials with complementary properties - rigid thermoplastics for pressure-resistant connecting parts and flexible thermoplastics for vibration-absorbing fluid lines, achieving both strength and weight reduction
2Adaptability or versatility
If multiple individual components and adapter elements are used, then adaptability and connection flexibility are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate components (fluid lines, connecting parts, and fastening elements) into integrated thermoplastic components manufactured in a single injection molding process, reducing the number of individual parts while maintaining connection flexibility through design-integrated attachment means
Solution Approach 2:
The connecting parts are designed with multi-functionality, combining fluid conduit, structural support, and fastening functions in single integrated components that can be universally applied to various mounting configurations without requiring additional adapter elements
3Ease of manufacture
If non-positive connections and adapter elements are used, then ease of assembly is improved, but reliability and tightness deteriorate due to leakage risks
Solution Approach 1:
The patent replaces mechanical non-positive connections (which rely on friction and fitting tolerances) with chemical bonding through material-to-material joining, where thermoplastic materials are heated and fused together to create monolithic joints that are as reliable as the material itself
Solution Approach 2:
The material-to-material joining process utilizes phase transition of thermoplastic materials from solid to molten state during heating, then back to solid upon cooling, creating strong molecular bonds between connecting parts and fluid lines that ensure long-term tightness without mechanical fasteners
4Manufacturing precision
If friction welding and material-to-material joining are used, then manufacturing precision and joint reliability are improved, but productivity and assembly speed may decrease
Solution Approach 1:
The patent incorporates attachment means and alignment features directly into the molded components during manufacturing, so that positioning and orientation are predetermined by the geometry of the parts themselves, eliminating the need for complex alignment operations during assembly
Solution Approach 2:
The thermoplastic materials and molded geometries are designed to be self-aligning and self-securing, where the materials themselves provide the bonding mechanism and the molded features provide automatic positioning, making the assembly process self-guiding and reducing skill requirements
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 reduces the number of components, ensures long-term tightness, absorbs vibrations, and maintains structural integrity under high pressure and temperature conditions, while minimizing assembly complexity and weight, thus addressing the complexity and weight issues of existing systems.
Implementation Method 1
connecting the first connecting part and the first fluid line by friction welding
Data Source
Figure 1~2
Figure 3~6
Figure 7~10
AI summary
The invention relates to a conduit arrangement (30) for a pressurized fluid, in particular for connecting a gearbox (20) to an oil cooler (28), with a first fluid line (32) and with a second fluid line (34), which can be connected to a housing (40) such as a gearbox housing by means of a connecting arrangement (36). The connecting arrangement (36) has a first connecting part (42) and a second connecting part (44), each having a through-channel (50), wherein at least one of the connecting parts (42, 44) is made of plastic, wherein at least one of the fluid lines (32, 34) is made of plastic, and wherein the plastic connecting part (42, 44) and the plastic fluid line (32, 34) are bonded together.