As-Molded Plastic Unit Cell Structures for Compact Fluid Flow
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Solution Overview
Problem
Existing plastic pipe and tube assemblies in fluid flow applications have a large footprint due to the need for multiple ports and fittings, which is undesirable in industries like pharmaceuticals and semiconductor fabrication where space is limited.
Innovation Solution
The method involves fabricating 'as-molded' plastic parts with snap-nest tooling structures that allow for interference fits without clamps, enabling efficient welding of plastic parts with short tube or pipe portions to create compact assemblies, using radiant heating to melt the ends, and aligning them for butt welding without the need for fasteners or tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple ports and fittings are used to create plastic pipe and tube assemblies, then the assemblies can perform complex fluid flow functions, but the footprint or size of the assemblies increases
Solution Approach 1:
The patent combines multiple ports and tube portions into a single integrated plastic part molded in one operation. The manifold assembly includes a first port, second port, first tube portion, and second tube portion all formed as one piece, eliminating the need for separate fittings and reducing the overall footprint while maintaining complex fluid flow functionality.
Solution Approach 2:
The patent employs snap-nest tooling structures where one plastic part is inserted into another during molding to define precise spacing and alignment. The first plastic part is snap-nested within the second plastic part, creating a compact nested configuration that reduces footprint while preserving multiple port functions.
2Reliability
If traditional welding tooling with clamps is used, then plastic parts can be securely held during welding, but the device complexity and setup time increase
Solution Approach 1:
The patent removes the complex clamp mechanism from traditional welding tooling and replaces it with a simple pin insertion feature. The first plastic part includes a pin insertion feature that receives a pin from the welding tooling, providing sufficient positioning stability without requiring clamps, thereby reducing device complexity while maintaining welding reliability.
Solution Approach 2:
The plastic part itself provides the positioning feature through its pin insertion feature, which self-aligns and secures the part in the welding tooling without requiring external clamping mechanisms. The part structure serves its own positioning function, eliminating the need for complex tooling.
3Area of stationary object
If as-molded parts with short tube portions are used, then the assembly footprint is reduced, but the welding process becomes more challenging
Solution Approach 1:
The patent incorporates a pin insertion feature and pin receive feature directly into the as-molded plastic parts during the molding process. This preliminary action of pre-forming precise positioning features ensures accurate alignment during welding, making the welding of short tube portions easier and more reliable while maintaining the compact footprint.
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
This approach reduces the footprint of fluid flow assemblies by allowing for high part density and efficient welding processes, resulting in compact, reliable, and space-saving fluid flow systems.
Implementation Method 1
positioning a radiant heating element in the gap without physically contacting the respective tube or pipe portions to heat the facing ends to a melted state
Implementation Method 2
providing relative motion between the first and second tooling structures along an axis to respective weld positions to bring the facing ends of the respective first and second plastic parts together, leaving the first and second tooling structures in said weld positions until the parts have cooled to weld the first and second parts
Data Source
AI summary
Methods and apparatus are described for producing welded assemblies of plastic parts for use in fluid flow applications. A unit cell structure is disclosed for use in an assembly. One embodiment is an as-molded plastic unit cell structure for use in fabricating welded fluid flow assemblies, the cell structure comprising a hollow tubular body portion having opposed first and second axial ports, a first hollow tubular portion extending axially from a first end of the tubular body portion and defining the first axial port, the first hollow tubular portion having a tube or pipe end configured for welding to another plastic part in a fabrication process for an assembly, and wherein the first tubular portion has a length in a range of 1 mm to 40 mm.