Conical Sleeve Plug Welding for Leak-Tight Insulated Pipe Joints
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Solution Overview
Problem
Existing methods for sealing holes in sleeves connecting insulated pipes often result in weak connections due to improper insertion of conical plugs, leading to compromised insulation properties over time as water and substances can penetrate, reducing the longevity of the insulation.
Innovation Solution
A plug system with a plug body and collar design that decreases in diameter from one end to the other, where the plug collar ensures correct alignment and increased welding surface area, allowing for a strong and reproducible seal when heated and inserted into a conical hole in the sleeve, along with an optional flat patch for additional sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conical plug is used to seal the hole in the sleeve, then the hole can be closed and sealed, but the connection is weak and may break due to improper insertion angle
Solution Approach 1:
A guide ring is introduced as an intermediary component between the conical plug and the hole. The guide ring features a guide surface that directs the plug during insertion, ensuring it enters at the correct angle without requiring high precision from the installer. This mediator component bridges the gap between the simple plug design and the need for precise alignment.
Solution Approach 2:
The guide surface on the guide ring performs preliminary alignment action before the plug actually enters the hole. By pre-establishing the correct insertion angle through the guide surface, the system ensures proper positioning is achieved automatically during insertion, eliminating the need for the installer to manually control the angle with high precision.
2Reliability
If a conical plug is inserted into the hole, then the hole can be sealed, but water and substances can still penetrate through weak connections over time
Solution Approach 1:
The guide ring acts as a mediator that ensures the plug is correctly positioned and sealed against the hole. By guaranteeing proper alignment and contact between the plug sealing surface and the hole, the guide ring creates a reliable, long-lasting seal that prevents water and substances from penetrating the insulation over time.
3Productivity
If technicians install plugs on site under tight schedules, then productivity is maintained, but insertion angle accuracy decreases leading to weak connections
Solution Approach 1:
The guide ring serves as a self-aligning intermediary that automatically ensures correct insertion angle during the installation process. This allows technicians to work quickly under tight schedules without compromising precision, as the guide surface does the alignment work automatically rather than requiring skilled manual positioning.
Solution Approach 2:
The guide ring provides self-aligning functionality during plug insertion. The guide surface automatically directs the plug into the correct angle as it enters the hole, making the system self-correcting and eliminating the need for precise manual control by the technician. This maintains high installation speed while ensuring consistent accuracy.
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 plug system provides a robust and reliable sealing solution that increases the lifespan of insulated pipes by preventing water and vapor ingress, with improved reproducibility and reduced human error during installation, especially beneficial for thin-walled sleeves.
Implementation Method 1
a special heating tool is used to simultaneously heat the plug and the inside surface of the hole to the same predetermined temperature
Implementation Method 2
the plug is pushed into the hole thereby creating a welding connection between the plug and the hole
Data Source
Figure 1~2b
Figure 3a~4c
Figure 5a~5b
AI summary
A system comprising: a joint in the form of a sleeve (200) or a wrap, the joint being for connecting insulated pipes, and at least one plug for closing at least one conical hole (202) in the joint, wherein the at least one plug comprises: a plug body having round cross-sectional diameters decreasing in size from a first end of the plug body to a second end of the plug body, and a plug collar (120) with a proximal surface and a distal surface opposite the proximal surface, wherein the plug body extends from the distal surface of the collar and has the largest cross-sectional diameter nearest the plug collar (120), wherein the at least one plug is made from a material being directly weldable in the at least one hole (202) in the joint when the at least one plug and the at least one hole (202) are heated to a pre-determined temperature.