Conical Manifold Geometry for Better Flow and Lower Material Use
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Solution Overview
Problem
Existing manifolds in pipework systems, such as those used in tap water and heating systems, face inefficiencies in liquid flow distribution and material usage, particularly when manufactured from plastic, as they lack optimized flow characteristics and material efficiency.
Innovation Solution
A conical manifold design with a decreasing inner cross-sectional area and a substantially equal wall thickness, allowing for reduced material usage and improved flow distribution, while maintaining structural integrity through a constant ratio of outer diameter to wall thickness, and featuring a larger convergent angle on the outer surface for additional material savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional manifold design with uniform cross-section is used, then the structural strength is maintained, but the flow characteristics are poor and material usage is inefficient
Solution Approach 1:
The patent applies parameter changes by transitioning from a uniform cross-section design to a conical cross-section design where the inner diameter varies along the flow direction. This geometric parameter change optimizes flow distribution characteristics while reducing material consumption in the manifold body.
Solution Approach 2:
The patent employs curvature principles by implementing a conical shape with specific convergence angles for both the inner and outer surfaces. This curved geometric approach improves flow characteristics by eliminating abrupt transitions and reduces material usage compared to a cylindrical design.
2Reliability
If the inner cross-sectional area is reduced in the direction of flow, then flow characteristics are improved, but manufacturing complexity increases
Solution Approach 1:
The patent resolves the manufacturing complexity issue by applying parameter changes in a controlled manner through defined convergence angles. The conical geometry with specific angular parameters can be manufactured using standard processes like centrifugal casting or CNC machining, balancing flow optimization with manufacturing feasibility.
3Loss of substance
If wall thickness is reduced to save material, then material usage decreases, but structural strength may be compromised
Solution Approach 1:
The patent applies local quality by implementing different wall thicknesses at different locations along the manifold. The wall thickness varies according to the conical geometry, providing sufficient structural strength where needed while minimizing material usage in less critical areas, achieving an optimal balance between strength and material efficiency.
4Loss of substance
If a conical design with varying wall thickness is used, then material savings are achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent manages manufacturing precision requirements by defining specific convergence angle parameters for the conical design. These angular parameters can be precisely controlled during manufacturing processes, and the design includes appropriate tolerances to ensure functional performance while achieving material savings.
Data Source
AI summary
A manifold (1) comprises a body (2) with a plurality of branch fittings (3) diverging therefrom. The inner surface of the body (2) is conical such that the inner cross-sectional area of the body (2) decreases in the direction of flow. The manifold (1) is particularly well suited for use in tap water systems. The manifold (1) can be manufactured e.g. from polyphenyl sulfone PPSU, polysulphone PSU, polyvinylidene fluoride PVDF, glass fiber reinforced polyamide PA, or cross-linked polyolefin plastic.