Welded Fluid Connector Assembly for Harsh Brake and Fuel Lines
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Solution Overview
Problem
Existing fluid systems in vehicles, such as brake and fuel systems, face challenges in maintaining reliable connections and interactions due to harsh environments and high pressures, requiring improved connection methods and interaction devices that can withstand corrosion and mechanical stress while allowing for efficient fluid flow and sensing capabilities.
Innovation Solution
A fluid interaction device with a weldable, tubular end portion that forms a welded joint with a quick connection device, utilizing thermoplastic materials and friction, laser, or infrared welding to create a robust and sealed connection, allowing for both passive and active fluid interactions, including sensing and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-severable or non-separable joints are used to connect line elements, then connection reliability is improved, but maintenance and exchange of line elements becomes difficult
Solution Approach 1:
The connection system is divided into two distinct parts: a permanent welded connection between the fluid interaction device and the quick connector, and a separable quick connection between the quick connector and fluid lines. This segmentation allows the fluid interaction device to remain reliably connected while enabling easy replacement of fluid lines through the quick-release mechanism.
2Ease of operation
If quick connectors with mechanical mechanisms are used, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The complex mechanical quick-connect mechanism is extracted from the fluid interaction device itself and placed in a separate, dedicated quick connector component. This allows the fluid interaction device to maintain a simpler structure with just the welded tubular connection, while the quick-connect functionality resides in the separate connector assembly.
3Ease of manufacture
If attaching portions like attaching rings or adhesives are used to affix sensors, then ease of manufacture is improved, but connection reliability deteriorates due to bending requirements and environmental harshness
Solution Approach 1:
The sensor interface portion is merged with the quick connector body to form an integrated assembly. The sensor is then permanently affixed to this integrated structure using reliable welding techniques, eliminating the need for separate attaching portions that would require bending or adhesive bonding in harsh environments.
4Manufacturing precision
If friction welding is used to join thermoplastic materials, then manufacturing precision is improved, but use of energy increases
Solution Approach 1:
The friction welding process utilizes the relative rotational movement between the tubular end portion and the quick connector body to generate friction heat directly at the joint interface. This self-heating mechanism eliminates the need for external heating sources, achieving precise welding while minimizing energy consumption.
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 provides a reliable, durable, and efficient fluid interaction system that addresses corrosion and mechanical stress issues, enabling effective fluid flow and sensing, while allowing for easy maintenance and exchange of line elements.
Implementation Method 1
the connection portion is formed as a weldable, tubular end portion so that the housing member can be connected to a joining portion of the fluid supply element by means of a welded joint
Implementation Method 2
utilizing thermoplastic materials and friction, laser, or infrared welding to create a robust and sealed connection
Implementation Method 3
utilizing thermoplastic materials and friction, laser, or infrared welding to create a robust and sealed connection
Data Source
AI summary
A fluid interaction device for establishing an interaction with a fluid, particularly a brake fluid or a fuel fluid. A housing member accommodates a fluid interaction portion. The fluid interaction portion is adapted to interact with a fluid within the housing member. The housing member further comprises a connection portion which can be connected to a fluid supply element. The connection portion is formed as a weldable, tubular end portion so that the housing member can be connected to a joining portion of the fluid supply element by means of a welded joint.