CPC無泄漏連接器的6個特點 - CPC 6 traits of non-spill connectors
Posted by Connector Tips Editor on Tuesday, February 3, 2015
By Grant Wilhelm, Senior Design Engineer, CPC (Colder Products Co.)
How quick disconnect connectors evolved for low-pressure fluid handling
用于低壓流體處理的快速斷開連接器是如何發展的
在討論聯軸器時，術語“無泄漏”描述了一種特定類型的連接器，旨在在斷開連接時將泄漏量減少到接近零。這通常是通過設計容納在連接器主體內的閥門來實現的。無泄漏初設計為用于高壓工業液壓應用的重型金屬接頭，現已發展成為一類塑料和金屬連接器，適用于需要少泄漏和空氣夾雜的各種流體處理應用。The term non-spill, when discussing couplings, describes a specific type of connector meant to reduce spillage to near zero whenever it is disconnected. This is often achieved through the design of the valves housed within the connector body. Originally designed as heavy-duty metal couplings for high-pressure, industrial hydraulic applications, non-spill has evolved into a category of plastic and metal connectors suitable for a variety of fluid-handling applications requiring minimal spillage and air inclusion. 
圖 1：專為電子冷卻而開發的防溢漏連接器，例如 CPC 的 LQ 系列，即使在長時間連接后也能提供超可靠、無滴漏的斷開連接。Figure 1: Non-spill connectors developed specifically for electronic cooling, such as CPC’s LQ Series, provide ultra-reliable, drip-free disconnections even after long periods of connection.
Shift to low-pressure
轉向低壓
初用于高壓應用的無泄漏快速斷開連接器是由機加工黃銅、鍍鋅鋼、不銹鋼和鋁制成的球和套筒耦合器組件。由于液壓應用中常見的高壓 - 高達 15,000 psi (1,030 bar) - 金屬是唯一能承受這種壓力的合理材料。塑料材料的使用是因為它們提供了低壓應用所需的強度。塑料降低了連接器的成本和重量，并解決了與化學兼容性相關的問題。The original non-spill quick disconnects for high-pressure applications were ball and sleeve coupler packages made from machined brass, zinc-plated steel, stainless steel and aluminum. Because of the high pressures common in hydraulic applications — up to 15,000 psi (1,030 bar) — metals were the only logical material to contain such pressures. Plastic materials came into use because they provide the strength required for lower-pressure applications. Plastics reduce the cost and weight of connectors and answer concerns related to chemical compatibility.
從設計角度來看，無泄漏快速斷開裝置的傳統特性包括齊平閥設計、金屬結構和承受高壓額定值的能力。平面閥設計可大限度地減少每次斷開連接時的溢出量，因此可作為非溢出連接器的參考。減少溢出是保持環境清潔、控制有害液體和保護工人的關鍵。From a design perspective, the traditional characteristics of a non-spill quick disconnect include a flush-face valve design, metal construction and the ability to withstand high pressure ratings. The flush face valve design minimizes the amount of spillage each time it is disconnected, thus the reference as a non-spill connector. This reduced spillage is key to maintaining a clean environment, containing harmful fluids, and protecting workers.
colder-soft-touch-overmold
圖 2：柔軟觸感包覆成型通過更好的人體工程學和顏色編碼增強了用戶體驗。
Figure 2: Soft-touch overmold enhances user experience through better ergonomics and color coding.
The need to evolve
發展的需要
一段時間以來，低壓流體處理應用一直使用初為高壓環境設計的無泄漏快速斷開裝置。然而，隨著無泄漏連接器的更多低壓用途的出現，很明顯，高壓接頭在低壓應用中用于連接柔性、半剛性和增強管的過度設計——當然也很昂貴。For some time, low-pressure fluid-handling applications have used non-spill quick disconnects originally designed for high-pressure environments. However, as more low-pressure uses for non-spill connectors emerged, it became clear that high-pressure couplings were over-engineered — and certainly costly — for connecting flexible, semi-rigid and reinforced tubing in low-pressure applications.
為了精確滿足低壓流體應用的無泄漏要求，一種新型接頭已經發展：低壓、占用空間小的熱塑性塑料和金屬快速斷開設計，可保持無泄漏性能特征。以下六個特性描述了為低壓環境量身定制的無泄漏連接器的演變。
To precisely meet the non-spill requirements of low-pressure fluid applications, a new category of couplings has evolved: low-pressure, small- footprint thermoplastic and metal quick disconnect designs that maintain non-spill performance characteristics. The following six traits describe the evolution of the non-spill connector tailored for low-pressure environments.
1. Maintenance of flush-faced valves
平面接頭的的維護
無溢流閥技術的設計并不新鮮；新的是齊平閥向用于低壓應用的撓性管的連接器的遷移。在低壓環境中的連接和斷開歷來是使用提升式閥門完成的（見圖 3）。這種閥門類型將液體截留在閥門密封件外側的閥腔中。盡管閥門已經關閉了流量，但剩余的流體量可能會從連接器“溢出”。相比之下，齊平閥（見圖 3），由于其設計，只允許在閥門表面涂上一層液體，從而幾乎消除溢出并確保重復無滴漏連接和斷開。夾雜物，或在每次連接期間進入流體系統的空氣，也通過齊平閥設計大大減少。從醫療器械和設備到化學品處理，接近零溢出和包含的好處在許多應用中變得非常重要。
The design of non-spill valve technology is not new; what is new is the migration of the flush-faced valve to connectors for flexible tubing used in low-pressure applications.Connecting and disconnecting in low-pressure environments was historically accomplished with a poppet-style valve (see figure 3). This valve style traps liquid in the valve cavity on the external side of the valve seal. Though the valve has shut off the flow, this remaining volume of fluid can “spill” from the connector. In contrast, the flush-face valve (see figure 3), due to its design, allows no more than a coating of liquid on the valve surfaces, thereby nearly eliminating spillage and ensuring repeated dripless connections and disconnections. Inclusion, or the air put into the fluid system during every connection, is also drastically reduced with flush-face valve design. The benefits of near zero spillage and inclusion have become important in many applications, from medical devices and equipment to chemical handling. 
colder-poppet-valves
圖 3：提升閥（左）憑借其設計，可以截留液體并具有更高的溢出量，而齊平閥（右）可大限度地減少斷開連接時的溢出量。
Figure 3: Poppet valves (left) by virtue of their design, can trap liquid and have a higher volume of spillage, while flush-faced valves (right) minimize the volume of spillage at disconnect.
2. Switch from metal to engineered polymers
從金屬轉向工程聚合物
由于液壓應用的壓力要求，初選擇金屬外殼和內部閥門用于防溢漏接頭。低壓環境不一定需要金屬外殼和內部閥門的性能屬性。只考慮金屬高壓聯軸器替代方案的設計工程師可能在重量、封裝尺寸、流動性能，尤其是成本的可用選擇方面受到限制。不銹鋼提供廣泛的化學兼容性，但也是昂貴的金屬選擇。
作為替代方案，工程聚合物在金屬作為行業標準的應用中獲得了實質性的立足點。減輕重量、高強度和剛度以及實現復雜零件幾何形狀的能力都是工程聚合物的優點。與金屬斷開產品相比，選擇聚合物連接器可以節省 50% 到 75%。一些防溢漏連接器還采用了觸感柔軟的包覆成型技術，以實現更好的人體工程學和顏色編碼（見圖 2）。其他產品采用玻璃填充聚丙烯主體，具有耐化學性和更高的耐用性（見圖 4）。
Metal housings and internal valves were originally chosen for non-spill couplings due to the pressure demands of hydraulic applications. Low-pressure environments do not necessarily require the performance attributes of metal housings and internal valves. Design engineers looking only at metal high-pressure coupling alternatives may be limited in the available selection of weight, package size, flow performance and, in particular, cost. Stainless steel offers the widest chemical compatibility, but is also the most expensive metal choice.
As an alternative, engineered polymers have gained a substantial foothold in applications where metal had been the industry standard. Reduced weight, high strength and rigidity and the ability to achieve complex part geometries are all benefits of engineered polymers. Choosing polymer connectors can provide savings of 50 to 75% compared to metal disconnect products. Some non-spill connectors also incorporate a soft-touch overmold for better ergonomics and color coding (see figure 2). Others feature a glass-filled polypropylene body that offers chemical resistance and increased durability (see figure 4).
CPC-NonSpill-Connector
圖 4：通過玻璃填充的聚丙烯主體實現了耐化學性和更高的耐用性。Figure 4: Chemical resistance and increased durability are attained through a glass-filled polypropylene body.
3. Low-pressure environments, minimal pressure drop
低壓環境，小壓降
在低壓流體處理應用中，系統通常在真空至 120 psi (83 bar) 的壓力范圍內運行。使用專為在 10,000 psi 范圍內運行的應用而設計的無泄漏快速斷開連接是過大的。專為低壓流體處理應用而設計的快速斷開裝置可以提供低溢出、低空氣夾雜和小壓降的所有理想特性。通過利用塑料和先進制造技術的使用以及高效、高流量閥門設計獲得的設計靈活性，低壓快速斷開與金屬對應物相比提供更高的流量和更低的壓降。
In low-pressure fluid-handling applications, systems typically operate in the pressure range of vacuum to 120 psi (83 bar). The use of non-spill quick disconnects designed for applications operating in the 10,000 psi range is overkill. A quick disconnect designed specifically for low-pressure fluid-handling applications can deliver all the desirable features of low spillage, low air inclusion and minimal pressure drop. Low-pressure quick disconnects provide higher flow and lower pressure drop compared to their metal counterparts by leveraging the design flexibility gained through the use of plastics and advanced manufacturing techniques, as well as their efficient, high-flow valve design. 4. Compact design
緊湊設計
許多需要無泄漏連接器的低壓應用也需要緊湊的設計，因為管徑較小，并且內部或難以接近的位置應用了許多無泄漏連接器。例如，用于液體冷卻的服務器機架或內部體外診斷設備的無泄漏設計需要盡可能緊湊，以大限度地減少使用的產品空間，并為技術人員提供連接和斷開它們的空間。當今日益緊湊的連接器部分是通過其內部設計實現的。一些制造商提供無泄漏連接器，可以連接內徑小至 1?16 英寸或更小的管道（見圖 5）
Many low-pressure applications requiring a non-spill connector also demand a compact design, due to both smaller diameter tubing sizes and the interior, or hard-to-access locations, where many non-spill connectors are applied. For instance, non-spill designs used in server racks for liquid cooling or inside in vitro diagnostic equipment need to be as compact as possible to minimize product real estate used and to allow room for technicians to connect and disconnect them.
Today’s increasingly compact connectors are achieved partially through their internal design. Some manufacturers provide non-spill connectors that can connect tubing with an inside diameter as small as 1?16 in. or less (see figure 5).
CPC-NonSpill-Connectors
圖 5：對于需要特別緊湊設計的應用，今天的防溢漏接頭可以連接小至 1?16 英寸的管道。拇指鎖扣便于操作員使用，并提供連接已建立的聲音確認。Figure 5: For applications requiring especially compact designs, today’s non-spill couplings can connect tubing down to 1/16 in. Thumb latches ease operator use and provide audible confirmation that connection has been established.
5. Ease of use
易于使用
高壓接頭的一個持久特性是用戶在連接和斷開接頭時可能會遇到物理困難。連接耦合器時，該過程可能需要很大的力。這種用戶不便在一些低壓快速斷開裝置的設計中得到了解決，引入了符合人體工程學的拇指閂鎖，使斷開連接的過程變得更加容易。一些新的無泄漏連接器為用戶提供的另一個好處是在建立安全連接時發出“咔噠”聲，這向操作員確認已建立連接（見圖 5）。
An enduring characteristic of high-pressure couplings is the physical difficulty users can have in connecting and disconnecting the couplers. When connecting the couplers, the process can require significant amounts of force. This user inconvenience is addressed in the design of some low-pressure quick disconnects with the introduction of an ergonomic thumb latch that makes the process of disconnecting much easier. Another user benefit provided by some new non-spill connectors is an audible “click” that sounds when a secure connection is made, which confirms for operators that a connection has been made (see figure 5).
6. Chemical compatibility
化學兼容性
對于某些低壓流體處理應用，需要考慮流體與連接器或其部件的化學兼容性。與液壓應用（流體和金屬不會相互反應）不同，低壓流體處理應用可能涉及與金屬發生反應的介質。為了解決這一潛在問題，連接器設計人員使用聚丙烯（對許多流體具有耐化學性）或其他工程熱塑性塑料。
某些應用還需要無金屬流路。實現此目的的一種方法是通過使用 O 形圈將彈簧與流路隔離。這確保了流體和任何金屬之間的一定程度的分離。O 形圈密封將流體流與閥門驅動彈簧分開，從而確保高純度流路非常適合半導體制造等應用。在一些無泄漏連接器中，涂層彈簧在流體和金屬之間提供了第二級分離。
實際應用
無泄漏連接器的許多實際應用都是從它們的高壓起源發展而來的。下面是幾個例子：
醫療器械和體外診斷設備 — 醫療器械的許多流體處理應用需要少的空氣混入，以確保準確性和程序效率。一些設備還需要能夠在不滴漏或溢出的情況下斷開管道，以防止接觸危險流體并保持安全和清潔的環境。用于實驗室或患者護理設施診斷的分析設備需要相同的無滴漏斷開連接，以保持介質完整性、防止接觸生物危害并保持安全的工作環境。
墨水管理 — 無論墨水是水基、溶劑基還是 UV 固化，任何溢出都是一個問題。與水性油墨一樣，溶劑型油墨會留下一團糟，但也可能產生有毒煙霧。因為 UV 墨水只有在暴露于紫外線下才會變干，所以用抹布擦去的少量溢出物在清理后仍會保持濕潤很長時間。防溢出連接器有助于將墨水保持在系統中——從源頭消除混亂——因此墨水永遠不會與用戶或設備組件接觸。
電子產品的液體冷卻 — 無泄漏連接器非常適用于液體冷卻應用。通過將水或冷卻劑的溢出減少到接近零，服務器機架技術人員可以放心地連接和斷開它們，而不必擔心滴水會損壞或破壞設備。顏色編碼有助于防止熱線和冷線之間的錯誤連接（見圖 1）。新的設計特點確保了適應長時間靜態連接的長期功能。
用于低壓應用的無泄漏快速斷開連接器的范圍不斷擴大，從封裝尺寸越來越小的玻璃填充聚丙烯連接器到專為液體冷卻應用設計的鍍鉻黃銅無泄漏連接器。前面的六個演變特征解釋了為什么以及如何設計今天的無泄漏連接器以滿足低壓流體處理環境的獨特要求。初作為高壓防溢漏接頭的產品已經超出了液壓的范圍，為許多行業帶來了防溢漏性能，而且很可能為今天在 CAD 程序屏幕上成型的未來產品帶來了好處。
For certain low-pressure fluid-handling applications, the chemical compatibility of the fluid and the connector, or its parts, needs to be considered. Unlike hydraulic applications—where fluid and metal do not react with each other—low-pressure fluid-handling applications can involve media that reacts with metal. To address this potential concern, connector designers use polypropylene (which offers chemical resistance to many fluids) or other engineered thermoplastics.
Some applications also require a metal-free flow path. One method to achieve this is to isolate the springs from the flow path through the use of an O-ring. This ensures a degree of separation between the fluid and any metal. The O-ring seals separate fluid flow from the valve actuation springs, thereby ensuring high-purity flow paths well suited to applications such as semiconductor manufacturing. In some non-spill connectors, coated springs give a second degree of separation between fluid and metal.
Real-world applications
Many real-world uses of non-spill connectors have evolved from their high-pressure origins. Below are a few examples:
Medical devices and in vitro diagnostic equipment — Many fluid-handling applications for medical devices require minimal air inclusion for accuracy and procedural efficacy. Some devices also require the ability to disconnect tubing without drips or spillage to prevent contact with hazardous fluids and to maintain a safe and clean environment. Analytical equipment used for diagnostics in laboratory or patient care facilities requires the same drip-free disconnect to maintain media integrity, prevent contact with biohazards and maintain a safe working environment.
Ink management — Whether ink is water-based, solvent-based or UV curable, any spillage is a problem. Like water-based inks, solvent-based inks leave a mess, but can also have noxious fumes. Because UV inks only dry under exposure to UV light, small spills wiped up with rags continue to stay wet long after cleanup. Non-spill connectors help keep ink in the system—eliminating the mess at the source—so ink never comes into contact with users or equipment components.
Liquid cooling of electronics — Non-spill connectors are ideal for use in liquid cooling applications. By reducing spillage of water or coolant to near zero, server rack technicians can confidently connect and disconnect them without fear of drips that can damage or destroy equipment. Color coding helps prevent misconnection between hot and cold lines (see figure 1). The latest design features ensure long-term functionality that accommodates prolonged static connections.
The range of non-spill quick disconnects for low-pressure applications continues to grow, from glass-filled polypropylene connectors in increasingly small package sizes to chrome-plated brass non-spills specifically designed for liquid cooling applications. The preceding six evolutionary traits explain why and how today’s non-spill connectors have been designed to meet the unique requirements of low-pressure fluid-handling environments. What started as a high-pressure non-spill coupling has expanded beyond the scope of hydraulics to bring non-spill performance to many industries—and very likely, to products of the future taking shape on CAD program screens today.
Terminology defined
術語定義
出于本次非泄漏技術討論的目的，經常使用以下術語。與任何技術主題一樣，理解和使用通用參考術語很重要。
For the purposes of this non-spill technology discussion, the following terminology is frequently used. As with any technical subject matter, it is important to understand and use common reference terminology.
溢出：每次斷開連接器時閥面之間釋放的液體體積。一滴水 = 0.05 毫升。傳統的帶閥的 3?8 英寸耦合器每個連接周期有 ~ 1 至 3 毫升或更多的溢出；CPC 無泄漏技術在低壓下，在相同的 3?8 英寸流動面積的情況下，每個連接周期將泄漏量減少到 0.01 至 0.03 毫升。
Spillage: The volume of liquid between the valve faces released every time the connector is disconnected. One drop of water = 0.05 ml. A traditional valved 3?8 in. coupler has ~ 1 to 3 ml or more spillage per connection cycle; CPC non-spill technology reduces this volume to 0.01 to 0.03 ml spillage per connection cycle with the same 3?8 in. flow area, at low pressures.
包含：每次連接連接器時進入系統的空氣量。傳統的帶閥 3?8 英寸耦合器在每個連接周期中含有約 2 毫升或更多的雜質；CPC 無泄漏技術在相同的 3?8 英寸流動面積下，將每個連接周期的體積減少到 ~ 0.4 毫升。
Inclusion: The volume of air put into a system every time the connector is connected. A traditional valved 3? 8 in. coupler has ~ 2 ml or more inclusion per connection cycle; CPC non-spill technology reduces this volume to ~ 0.4 ml inclusion per connection cycle with the same 3?8 in. flow area.
泄漏：連接或斷開連接時從連接器中泄漏的介質。在設計良好的連接器中，無論其溢出量規格如何，都不應出現泄漏。
Leakage: Media that leaks out of the connector while connected or disconnected. In a well-designed connector, regardless of its spillage volume specifications, there should be no leakage.
流動面積：流體或氣體介質流經的面積。用于指定接頭尺寸以滿足管道尺寸、壓降、流速等要求。
Flow Area: The area through which the fluid or gas media travels. Used to specify coupling size to meet requirements of tubing size, pressure drop, flow rate, and so on.
key words: colder-non-spill-connectors CPC (Colder Products Co.)
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