Battery Electrofusion Tool With Pre-Checks for Pipe Welding

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Solution Overview

Problem

Existing electrofusion tools relying on AC power sources are limited in portability and lack comprehensive pre-operation checks to ensure battery capacity, temperature, and current compatibility for efficient and safe plastic pipe welding.

Innovation Solution

A battery-operated electrofusion tool with integrated pre-checks to verify peak operating current, battery charge, and temperature compatibility before initiating the welding process, using rechargeable battery packs and an electronic control unit to manage power distribution and ensure safe operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If AC power source is used for electrofusion tool, then power supply stability is improved, but portability deteriorates

Engineering Contradiction:

Improvepower supply stabilityVSAvoidportability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the AC power system with a battery-powered electrical system, enabling the electrofusion tool to operate portably while maintaining sufficient power delivery capacity through carefully selected battery configurations and power management circuits

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If comprehensive pre-checks are added to verify battery capacity, temperature, and current compatibility, then operational safety is improved, but device complexity increases

Engineering Contradiction:

Improveoperational safetyVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent performs preliminary checks of battery capacity, temperature, and current compatibility before initiating the electrofusion process. The control system automatically verifies these parameters and only allows operation when all conditions are satisfied, preventing unsafe operations without requiring complex manual verification procedures

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent incorporates feedback mechanisms that continuously monitor battery status and system parameters, providing real-time information to the control system which adjusts operation accordingly. This automated feedback loop ensures safety while maintaining relatively simple device architecture

Inventive Principle:

Principle #23Feedback

3Ease of operation

If battery pack is used instead of AC power source, then portability is improved, but power output capacity deteriorates

Engineering Contradiction:

ImproveportabilityVSAvoidpower output capacity

Core Design Contradiction:

Ease of operationVSPower

Solution Approach 1:

The patent carefully selects and configures battery packs with appropriate voltage, capacity, and discharge rate parameters to meet the power requirements of the electrofusion tool. By optimizing battery chemistry, configuration, and power management, the system achieves sufficient power output for welding applications while maintaining portable battery-powered operation

Inventive Principle:

Principle #35Parameter changes

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

Ensures safe and efficient welding of plastic pipes by preventing overloading, overheating, and ensuring sufficient battery capacity, enhancing portability and reliability in electrofusion processes.

Implementation Method 1

a battery receptacle to selectively receive a rechargeable battery pack

Methodology Applied

Scientific EffectBattery (electricity): Battery (electricity)

Implementation Method 2

electrical leads extending from the housing and configured to transfer a current from the battery pack to the pipe fitting

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

electrical leads extending from the housing and configured to transfer a current from the battery pack to the pipe fitting for permanently joining the pipe ends together

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250340021A1Electrofusion tool

Publication Date: 2025.11.06 MILWAUKEE ELECTRIC TOOL CORP

AI summary

An electrofusion tool used in joining pipe ends of plastic pipes together via a pipe fitting during an electrofusion process includes a housing, a battery receptacle to selectively receive a rechargeable battery pack, and electrical leads extending from the housing and configured to transfer a current from the battery pack to the pipe fitting for permanently joining the pipe ends together. The electrofusion tool also includes an electronic control unit configured to initiate a first system pre-check to determine whether an estimated peak operating current is less an output capacity of the electrofusion tool, a second system pre-check to determine whether an estimated electrical energy of the battery pack is less than a remaining charge capacity of the battery pack, and a third system pre-check to determine whether an estimated operating temperature of the battery pack is less than a set temperature threshold of the battery pack.