Conformable Magnetic Contact Member for Non-Planar Pipe Surfaces
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Solution Overview
Problem
Existing magnetic-type work clamps face challenges when used on non-planar surfaces, such as pipes, requiring removal of non-conductive coatings and struggling to establish effective electrical contact due to curvature and internal diameter variations.
Innovation Solution
A conformable contact member with a base and conductive bristles secured by a magnet, allowing the apparatus to conform to the target surface and provide increased contact area without the need for fixtures, enabling secure electrical connection to both inside and outside surfaces of pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional work clamp is used on a pipe surface, then electrical contact can be established on planar surfaces, but the clamp cannot effectively contact non-planar surfaces such as curved pipe surfaces
Solution Approach 1:
The patent applies curvature by using a flexible contact member with bristles that can conform to curved pipe surfaces. The contact member is designed to bend and adapt to the cylindrical geometry of pipes, allowing reliable electrical contact on non-planar surfaces while maintaining contact stability through the flexible bristle structure.
Solution Approach 2:
The patent employs a flexible contact member comprising a flexible base and conductive bristles that can deform to match the contour of pipe surfaces. This flexibility allows the contact member to maintain reliable electrical contact on curved and non-planar surfaces without requiring rigid structural support.
2Reliability
If a work clamp is used to establish electrical contact, then current return path is provided, but the clamp obstructs the welder's workspace
Solution Approach 1:
The patent divides the contact system into separate functional elements: a magnetic component for attachment and a flexible contact member with bristles for electrical connection. This segmentation allows the contact member to be positioned optimally for welding access while the magnetic component provides secure attachment, reducing workspace obstruction.
Solution Approach 2:
The patent transitions from a two-dimensional planar contact approach to a three-dimensional flexible bristle structure that can wrap around and conform to pipe surfaces. This dimensional change allows the contact to be established on the pipe surface without the clamp body obstructing the welder's access to the welding area.
3Force
If magnetic-type work clamps are used on pipes, then attachment to the pipe surface is achieved, but non-conductive coatings on the pipe surface prevent effective electrical contact
Solution Approach 1:
The flexible contact member with conductive bristles can penetrate or bridge through non-conductive coatings on the pipe surface. The bristle structure allows the conductive material to make direct contact with the underlying conductive pipe surface even when coated, maintaining reliable electrical contact while the magnetic component provides attachment force.
4Adaptability or versatility
If the internal diameter of a pipe varies from part to part, then different pipe sizes must be accommodated, but establishing more than point or line contact becomes difficult
Solution Approach 1:
The patent uses a dynamic, flexible contact member that can adjust its shape and conform to pipes of varying diameters. The flexible base and bristle structure allow the contact member to adapt to different internal diameters while maintaining a broad contact surface area, transitioning from fixed-geometry clamps to a deformable contact system.
Solution Approach 2:
The flexible contact member can deform to match the specific diameter of each pipe, expanding or contracting its contact surface area accordingly. This flexibility ensures that whether the pipe has a small or large internal diameter, the contact member can establish broad surface contact rather than just point or line contact.
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 reliable and improved electrical connections to non-planar surfaces, eliminating the need for coating removal and accommodating surface irregularities, while allowing for easy repositioning without obstructing the welder's workspace.
Implementation Method 1
a magnet secured to the base to thereby secure the bristles against the target surface
Data Source
Figure 1
Figure 2
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AI summary
An apparatus with (a) a conformable contact member with a base and a contact layer; and (b) a magnet integral with or attached to the base, wherein, when the apparatus is placed on a target surface, the magnet and the target surface attract each other such that the contact layer is secured against the target surface.