Pipe connector

Abstract

A pipe connector (1) comprising a first pipe portion (10) comprising a first connector end (11), a second pipe portion (20) comprising a second connector end (21), and a collar (30) for receiving the first and second connector ends (11, 21), wherein the collar (30) comprises a heating wire for use in an electrofusion welding process and, wherein the pipe connector (1) is configured such that when the first and second connector ends (11, 21) are received in the collar (30), at least one of the first and second pipe portions (10, 20) is obliquely angled relative to the collar (30).

Description

[0001] Pipe Connector

[0002] Technical field

[0003] The present invention relates to the field of pipes and pipe connectors. More specifically, the invention relates to pipe connectors which provide bends and angled sections.

[0004] Background

[0005] In both domestic and industrial buildings there is a requirement to remove both sewage (soil) and grey water and to feed such waste into the sewer network. Typically, this is achieved by a drain-waste-vent system, a major component of which is the soil stack. A soil stack is a large diameter vertical pipe which acts as a common waste pipe in to which the other soil and grey water pipes from the building feed and which connects to the sewer at or below ground level.

[0006] To simplify installation in some construction projects, some or all of the plumbing system can be pre-fabricated. Often this includes pre-fabricating the soil stack in sections and connecting them in situ. In some installations, pre-plumbed units (pods) such as complete bathroom suites can be provided. The pods or prefabricated soil stack sections can be quickly placed in the desired location within the building, for example by hoisting them into position with a crane to provide a bathroom suite, without requiring extensive installation time. Although the pods and soil stack sections reduce the amount of plumbing and installation required on site, it can often be difficult to reliably and securely connect the pod plumbing to further pods or soil stack sections. In some cases, the vertical alignment of soil stack sections e.g. between floors in the building, may be inaccurate and require mitigation. Since soil stacks are formed from rigid pipe, such mitigation can be difficult.

[0007] In some cases, complex building designs may require bespoke soil stack configurations. Making or adjusting existing components to provide a custom configuration is time consuming and requires both manufacturers and installers to stock a wide range of different components which can be assembled to produce the final design. The present invention seeks to mitigate or ameliorate one or more of the above problems.

[0008] Summary of the invention

[0009] According to a first aspect of the invention, there is provided a pipe connector. The pipe connector may comprise a first pipe portion. The first pipe portion may comprise a first connector end. The pipe connector may comprise a second pipe portion. The second pipe portion may comprise a second connector end. The pipe connector may comprise a collar. The collar may be for receiving the first and second connector ends. The collar may comprise a heating wire for use in an electrofusion welding process. The pipe connector is configured such that when the first and second connector ends are received in the collar, at least one of the first and second pipe portions is obliquely angled relative to the collar.

[0010] By ‘obliquely angled’, it will be understood that the first and second pipe portions each define an axis (e.g. a central axis), and at least one of the axes may be obliquely angled relative to the collar.

[0011] In one series of embodiments, both the first and second pipe portions are obliquely angled relative to the collar. In some embodiments, the first and second pipe portions are obliquely angled relative to each other. In some embodiments, the oblique angles relative to the collar are the same.

[0012] The pipe connector is advantageous, since it eliminates the need for a mechanical connection e.g. requiring flexible gaskets such as rubber O-rings. The pipe connector can be assembled in situ to provide a bend in a soil stack or similar pipe work and then electrofused. Thus it provides a permanent and watertight pipe connector while simplifying installation. The first and second pipe portions may be oriented to provide the desired angle and / or direction, and then connected together to provide the desired bend. The pipe connector is thus more adaptable than moulded bends that are manufactured in common angles. At least one of the pipe portions may be rotatable relative to the other pipe portion and / or the collar. In some embodiments, said pipe portion may be rotatable when the pipe connector is assembled. In some embodiments, the second pipe portion is rotatable relative to the first pipe portion and the collar. The first pipe portion and collar may be rotationally fixed relative to each other. By one of the pipe portions being rotatable, the direction of the pipe connector can be rotated as required. In embodiments wherein both pipe portions are obliquely angled relative to the collar, the angle of the bend may be variable by rotating one or both of the pipe portions e.g. the second pipe portion. The bend in the pipe connector may be continuously variable. The electrofusion welding process may be configured to rotationally fix the second pipe portion relative to the first pipe portion and / or the collar.

[0013] The pipe portions may be configured such that in a first condition, the first and second pipe portions are coaxial. The pipe portions may be configured such that in at least a second condition, the first and second pipe portions are angled relative to each other. The pipe portions may be configured such that the internal surfaces of the first and second pipe portions are approximately continuous e.g. there is no step between the two components.

[0014] The pipe connector may be configured such that the first and second pipe portions have a maximum angle of 25°. E.g. the first and second central axes of the first and second pipe portions may have a maximum angle of 25°. It will be understood that the acute angle will be used herein for the measurement of the intersecting axes. As will be understood, where the first and second pipe portions are coaxial, the angle will be 0°. In some embodiments, the pipe connector may be configured such that the first and second pipe portions have a maximum angle of 30°, 40°, 45°, 50°, 60°, 70°, 80°, or 90°. The pipe connector may be configured such that the first and second pipe portion has an angle relative to the collar (e.g. to an axis defined through the collar) of half the maximum angle.

[0015] The first and / or second connector end may comprise a mating surface for mating with a corresponding surface on the collar. The mating surface(s) may be cylindrical. The mating surface(s) may be obliquely angled relative to the pipe portion(s). The mating surface(s) may be parallel and / or coaxial with the collar e.g. a corresponding and / or an internal surface of the collar. For example, the corresponding surface of the collar and the mating surface(s) may be concentric.

[0016] The corresponding surface of the collar may comprise a fusion surface. The corresponding surface of the collar may comprise the heating wire. In use, the corresponding surface is weldable to the mating surface e.g. plastics welding such as via electrofusion welding.

[0017] The collar may comprise at least one power connector for connecting the heating wire to a power source. The power connector may be an electrical connector and / or plug or socket. The collar may comprise a pair of power connectors defining a positive and negative terminal. The heating wire may be a resistive heater.

[0018] The pipe portions and / or collar may be formed from High Density Polyethylene (HDPE), low or medium density polyethylene, polypropylene, PVC, polybutylene, ABS or any other suitable plastics material.

[0019] The first and second pipe portions may each comprise a tail portion for connecting to a further pipe or pipe connector. The tail portion may comprise a surface for sealing to a soil pipe. The tail portion may be sealed to a soil pipe by any suitable method. For example, the tail portion may be joined to a soil pipe by any one or more of plastics welding, adhesion with an adhesive, or one or more mechanical fasteners. Plastics welding may comprise any one or more of butt welding, electrofusion welding, solvent welding, ultrasonic welding, induction welding, friction welding, laser welding, IR welding or Radio Frequency (RF) welding. Butt welding and electrofusion are particularly advantageous, since they are reliable and inexpensive processes.

[0020] The first and second connector ends may each comprise snap-fit connectors for connecting to each other. The first and / or second of the connector ends may comprise a projecting portion and the other of the first and / or second connector ends may comprise a groove for receiving the projecting portion.

[0021] The groove may extend the full circumference of one of the connector ends. Alternatively, the groove may be segmented and extend around portions of one of the connector ends. The groove may be formed in a wall or walls extending from one of the connector ends. The walls may be flexible e.g. resiliently flexible. The wall or walls may be configured to flex over the projecting portion during assembly to provide said snap- fit. The skilled person will understand that other connection arrangements may be used.

[0022] The collar may comprise one or more teeth. The first and / or second connector ends may comprise one or more recesses for receiving the tooth therein. The recess may comprise one or more mouths. The one or more mouths may be located between the walls of one of the connector ends.

[0023] According to a second aspect of the invention, there is provided a kit of parts for forming the pipe connector described herein. The kit of parts may comprise a first pipe portion, second pipe portion and a collar as described herein. In some embodiments, the kit of parts may comprise more than one first pipe portion, second pipe portion and / or collar. The plurality of first pipe portions, second pipe portions and / or collars may have different sizes e.g. a different internal radius or external radius. The plurality of pipe portions, second pipe portions and / or collars may comprise different materials.

[0024] According to a third aspect of the invention, there is provided a pipe connector assembly comprising a first pipe connector as described herein, a second pipe connector as described herein, and one or more further connectors for connecting the pipe portions of the first and second pipe connectors. In some embodiments, the assembly further comprises a pipe portion and a second further connector.

[0025] Specific Description

[0026] Embodiments of the invention will now be described with reference to the following drawings, in which:

[0027] Figure 1 is a perspective view of a pipe connector in a first condition;

[0028] Figure 2 is a cross section through the pipe connector of Figure 1;

[0029] Figure 3 is an exploded diagram of the pipe connector of Figure 1;

[0030] Figure 4 is a perspective vie of a pipe connector in a second condition;

[0031] Figure 5 is a cross section through the pipe connector of Figure 3; and Figure 6 is a diagram of a pipe connector assembly. Turning now to Figures 1 to 3, there is shown a pipe connector 1 in a first condition. The pipe connector has a first pipe portion 10, a second pipe portion 20 and a collar 30.

[0032] The first and second pipe portions 10, 20 are short lengths of pipe having a diameter and wall thickness to match existing conventional pipes e.g. soil stacks. The first pipe portion 10 has a first connector end 11 received within the collar 30 and a first tail end 12 at the other end thereof. The first pipe portion 10 defines an axis extending through the centre thereof e.g. a first pipe axis as denoted by the dashed line A. The second pipe portion 20 has a second connector end 21 received within the collar 30 and a second tail end 22 at the other end thereof. The second pipe portion 20 defines an axis extending through the centre thereof e.g. a second pipe axis as denoted by the dashed line B. The first and second tail ends 12, 22 are flat surfaces extending perpendicularly to the axes A and B respectively, and can be joined to a further length of pipe in the conventional manner e.g. via plastics welding such as butt welding, adhesion with an adhesive, or one or more mechanical fasteners or connectors. For example, the tail ends 12, 22 may be configured to have the same size and shape as a 56mm, 75mm, 82mm, 110mm, or 160mm diameter soil pipe.

[0033] The first and second connector ends 11 , 21 each have a cylindrical mating surface 13, 23 which extends around their circumference. The mating surfaces 13, 23 are obliquely angled relative to the first and second pipe portions 10, 20 i.e. relative to the first and second pipe axes A, B, as best shown in Figure 3. The first and second mating surface 13, 23 are coaxial with each other such that the outer mating surfaces are parallel with each other. The internal surfaces of the first and second pipe portions are also equivalent, such that they form a relatively seamless transition when butted together.

[0034] The collar 30 is an annular ring which extends fully around the first and second connector ends 11 , 12. The collar 30 is thus obliquely angled relative to the first and second pipe axes A and B. The oblique angle of the collar 30 is the same as the oblique angle of the mating surfaces 13, 23 such that the internal surface of the collar 30 closely abuts the mating surfaces 13, 23 of the first and second connector ends 11 , 21. The first and second pipe portions 10, 20 and the collar 30 are all connected to each other to form a single adjustable component. The first pipe portion 10 and the collar 30 are rotationally locked together once assembled, but importantly, the second pipe portion 20 is rotatable relative to the first pipe portion 10 and the collar 30. In the embodiment shown, the collar 30 and mating surfaces 13, 23 have a 12.5° angle relative to the first and second pipe axes A and B. In the first condition, as shown in Figures 1 and 2, the oblique angles are aligned such that the angle 0 is 25° i.e. the pipe connector define a 25° bend.

[0035] Turning now to Figures 4 and 5, the second pipe portion 20 has been rotated by 180°. The oblique angles of each of the pipe portions relative to the collar 30 now cancel each other out and the pipe connector forms a single straight pipe section. The first and second pipe axes are now coaxial and collinear, as indicated by the axis AB in Figure 5. It will be understood that any relative angle of the first and second pipe portions 10, 20 between 0° and 25° is achievable by rotation of the pipe portions relative to each other (i.e. by rotation of the second pipe portion).

[0036] Further details of the connection of the first and second pipe portions 10, 20 and the collar 30 will now be described with reference to Figure 3. The first connector end 11 is provided with a first ring wall 18 which extends around the internal surface of the first connector end and which cooperates with a second ring wall 28 of the second pipe portion 20. As shown in Figure 2, the first ring wall 18 is inwardly tapered (i.e. towards the central axis) and the second ring walls 28 is tapered outwardly (i.e. away from the central axis) such that they can cooperate and nest together, forming an approximately continuous internal surface of the pipe connector 1. The first ring wall 18 sits inside, i.e. radially internally, of the second ring wall 28. The tapered surfaces assist in guiding the first and second ring walls into position and to provide an effective connection.

[0037] The first pipe connector end 11 has a series of three mouths 14 arranged around the circumference facing the second pipe portion 20. The mouths 14 are recesses which are open on their leading edge in order to receive teeth 34 of the collar 30 therein. The teeth 34 prevent relative rotation of the collar 30 and first pipe portion 10. Each mouth 14 receives one of the three teeth 34. The mouths 14 may each define a stop surface 9 (visible in respect of two of the mouths 14 in Figure 3). The teeth 34 abut the stop surfaces 9 when the first pipe connector end 11 is received within the collar 30, and as such, the stop surfaces 9 is configured to control the extent to which the first pipe connector end 11 is received within the collar 30. Since the first pipe connector end 11 engages the second pipe connector end 21 (when the first and second pipe connector ends 11, 21 are received within the collar 30) the stop surfaces 9 also control the extent to which the second pipe connector end 21 is received within the collar 30. In some arrangements, the stop surfaces 9 may be designed such that the extent to which the first and second pipe connectors 11, 21 are received within the collar 30 is equal (that is, they are received within the collar 30 at equal depths).

[0038] Between each of the mouths 14 are walls 16 which extend concentrically with the first ring wall 18 around a portion of the first connector end 11. The internal surface of the walls 16 are provided with a lip 17 which protrudes inwardly and defines a groove between the lip 17 and the rest of the first connector end 11. Each wall 16 is provided with an aperture 15 therein configured such that the walls 16 can flex resiliently by a small distance.

[0039] The second pipe portion is provided with a series of locking projections 25 which extend radially outwardly from the second ring wall 28. The locking projections 25 are arcuate and extend around a portion of the ring wall 28. The locking projections 25 extend only a short distance corresponding with the depth of the groove defined by the lip 17 and the rest of the first connector end 11. The locking projections 25 and lips 17 on the walls 16 thus form a snap-fit connection when the second connector end 21 is inserted into the first connector end 11. The locking projections 25 prevent the second pipe portion 20 from being easily detached from the first pipe portion 10. The locking projections 25 allowing rotation of the second pipe portion 20 relative to the first pipe portion 10, since they can freely run in the groove defined above between the lip 17 and the rest of the connector end 11.

[0040] As shown in Figure 3, the collar is provided with a heating wire 32 embedded within the internal surface of the collar facing and corresponding with the first and second mating surfaces 13, 23. The collar has a pair of power connectors 31 which are operatively connected to the heating wire 32 and configured to receive a wire or plug connector for connecting the heating wire 32 to an energy source. In use, the pipe connector 1 is assembled by first inserting the first connector end 11 of the first pipe portion 10 into a first side of the collar 30, and optionally rotating one of the components until the teeth 34 are located within the mouths 14. Subsequently, the second connector end 21 of the second pipe portion 20 is inserted into the opposite side of the collar 30 and pushed firmly against the first connector end 11. The walls 16 have sufficient flexibility that the lips 17 can be pushed outwardly by the locking projections 25 until they have bypassed them, whereby they relax back into place securing the first and second pipe portions 10, 20 together. This action nests the first and second ring walls 18, 28 together, with alignment aided by their cooperating tapers. The collar 30 is thus held captive by the teeth 34 being located within a recess defined by the mouths 14 and the shoulder 29 of the second connector end.

[0041] During an installation procedure of a soil stack, the pipe connector 1 is particularly advantageous since it provides a variable angle bend which can be used to mitigate inaccuracies in the rest of the soil stack system and / or to produce bespoke non-linear designs without requiring a wide range of components having different angle bends. In the embodiment shown, the angle of the first and second pipe portions 10, 20 relative to each other can be varied between 0° and 25°. As shown in Figure 6, multiple pipe connectors 1A, 1B can be connected together using connecting rings 3 and a length of pipe 5. The assembly of pipe connectors 1 , connecting rings 3 and pipe 5 can be used to form bends with a large angle or in a reversed configuration to form an S-bend (as shown in Fig 6) or similar. An S-bend can be used to compensate for errors in alignment of soil stack portions e.g. by joining a first and second pipe connector 10, 20, the tail ends 12, 22 at the top and bottom of the joined pipe connectors 1 A, 1 B can be arranged to provide a lateral offset as shown by the arrow C. By increasing the angles of the first and second pipe connectorslA, 1B, the offset can be increased. If the angles of the first and second pipe connectors 1A, 1 B are the same, and arranged in reverse, the first pipe portion 10 of the first pipe connector 1A and the second pipe portion 20 of the second pipe connector 1 B will be parallel i.e. their pipe axes A, B will be parallel to each other.

[0042] The tail ends 10, 20 of the pipe connector 1 can be simply butt welded onto the end of a prefabricated or an existing soil stack in the conventional manner, or can be adhesive welded, mechanically secured etc. In situ, such a buttweld may be difficult, and the tail ends 12, 22 and the soil stack may be connected using an electrofusion connector in the conventional manner. Since the first pipe portion 10 and collar 30 are not rotatable relative to each other, it is important that the first pipe portion 10 is joined to a soil stack with the correct orientation. The second pipe portion 20 can then be rotated to provide the desired angle. To permanently join the first and second pipe portions 10, 20, the collar 30 can be connected to a power source in order to heat the heating wire 32 and form an electrofusion weld between the internal surface of the collar 30 and the first and second mating surfaces 13, 23 of the first and second connector ends 11, 21 respectively. The electrofusion weld between the components thus provides a permanent and water proof joint.

[0043] The pipe connector 1 can be formed from any suitable plastics material, such as High Density Polyethylene (HDPE), PVC, polypropylene, polybutylene, ABS, low or medium density polyethylene, or other suitable plastics material.

[0044] In an alternative series of embodiments (not shown) the first pipe portion may be fully or partially rotatable relative to the collar. For example, the mouths 14 may be extended such that a small amount of rotation of the collar is possible. Alternatively, the collar and first pipe portion may be connectable by an alternative mechanism which permits full rotation, e.g. by providing an annular groove on the outer surface of the mating surface into which teeth can be located and which allows free rotation of the collar.

Claims

CLAIMS:

1. A pipe connector comprising: a first pipe portion comprising a first connector end, a second pipe portion comprising a second connector end, and a collar for receiving the first and second connector ends, wherein the collar comprises a heating wire for use in an electrofusion welding process and, wherein the pipe connector is configured such that when the first and second connector ends are received in the collar, at least one of the first and second pipe portions is obliquely angled relative to the collar.

2. The pipe connector according to claim 1 , wherein both first and second pipe portions are obliquely angled relative to the collar.

3. The pipe connector according to claim 2, wherein the oblique angles relative to the collar are the same.

4. The pipe connector according to any one of the preceding claims, wherein at least one of the pipe portions is rotatable relative to the other pipe portion and / or the collar.

5. The pipe connector according to claim 4, wherein the pipe portions are configured such that in a first condition, the first and second pipe portions are coaxial, and wherein in at least a second condition, the first and second pipe portions are angled relative to each other.

6. The pipe connector according to claim 4 or 5, configured such that the first and second pipe portions have a maximum angle of 25°.

7. The pipe connector according to any one of the preceding claims, wherein the first and / or second connector end comprises a mating surface for mating with a corresponding surface on the collar.

8. The pipe connector according to any one of the preceding claims, wherein the corresponding surface of the collar comprises a fusion surface comprising the heating wire, and wherein in use, the fusion surface is weldable to the mating surface.

9. The pipe connector according to any one of the preceding claims, wherein the collar comprises at least one power connector for connecting the heating wire to a power source.

10. The pipe connector according to any one of the preceding claims, wherein the pipe portions and collar are formed from High Density Polyethylene, low or medium density polyethylene, polypropylene, PVC, or ABS.

11. The pipe connector according to any one of the preceding claims, wherein the first and second pipe portions each comprise a tail portion for connecting to a further pipe or pipe connector.

12. The pipe connector according to any one of the preceding claims, wherein the first and second connector ends comprise snap-fit connectors for connecting to each other.

13. The pipe connector according to any one of the preceding claims, wherein the first and / or second connector end comprises a projecting portion and the other of the first and / or second connector end comprises a groove for receiving the projecting portion.

14. The pipe connector according to claim 13, wherein the collar comprises a tooth and the first and / or second connector ends comprise a recess for receiving the tooth therein.15 A kit of parts for forming a pipe connector according to any one of the preceding claims, the kit of parts comprising: at least one first pipe portion comprising a first connector end, at least one second pipe portion comprising a second connector end, andat least one collar for receiving the first and second connector ends, wherein the at least one collar comprises a heating wire for use in an electrofusion welding process and, wherein the collar is configured such that when the first and second connector ends are received, at least one of the first and second pipe portions is obliquely angled relative to the collar.

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