Corrugated Tubing Compression Tool for Solar Installations
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Solution Overview
Problem
Existing methods for flaring metal tubing ends to prevent nut slippage during transport or installation are either damaging, expensive, or fail to address jagged ends and bur removal, leading to leaks.
Innovation Solution
A hand-held compression tool with a tube clamp and force-transmission cylinder that compresses and flattens corrugated tubing ends, featuring a deburring rim to smooth burs, ensuring secure nut attachment and preventing leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a hammer is used to strike the tubing end to flare it, then the tubing end can be widened, but the hammer striking force is uneven which may damage the tubing and create non-uniform flared ends
Solution Approach 1:
The patent combines the flaring operation with a deburring operation into a single integrated tool. The flaring tool includes both a flaring mechanism and a deburring blade that contacts the tubing end simultaneously, eliminating the need for separate operations and ensuring uniform flaring without damage from uneven hammer strikes
Solution Approach 2:
The patent replaces the manual hammer striking method with a mechanically actuated flaring mechanism that applies controlled, uniform force through threaded engagement. The impact wrench provides consistent rotational force that translates to uniform axial compression, replacing the uneven manual hammer strikes
2Shape
If silicone compression and isolation rings are used to widen the tubing end, then the end can be flared, but these rings are expensive and subject to cracking under high temperature, pressure and mechanical stress
Solution Approach 1:
The patent replaces expensive silicone rings with a durable metal flaring tool that creates a permanent flare. The tool itself is designed to be reusable and robust, eliminating the need for disposable or semi-disposable silicone components that crack under stress
Solution Approach 2:
The patent uses a metal flaring tool with composite functional elements - the impact driver portion and the deburring blade work together as a composite system to achieve both flaring and bur removal, replacing the single-material silicone ring approach
3Length of moving object
If metal tubing is cut from tubing stock, then the tubing can be sized correctly, but the cut end becomes jagged with sharp burs that can cut washers and seals
Solution Approach 1:
The patent merges the flaring operation with a deburring operation into a single integrated tool. The flaring tool includes both a flaring mechanism and a deburring blade that contacts the tubing end simultaneously, eliminating the need for separate operations and ensuring uniform flaring without damage from uneven hammer strikes
Solution Approach 2:
The deburring blade is positioned to contact and remove burs before the flaring operation completes. This preliminary deburring action prevents burs from interfering with subsequent sealing operations and eliminates the harmful effect of sharp edges before they can damage washers or seals
4Device complexity
If the tubing end is not flared or widened, then the tubing remains simple in structure, but the nut can inadvertently slide off the tubing during transport or installation
Solution Approach 1:
The patent creates a flared end that provides a mechanical stop for the nut, making the potential energy of the nut-zero position stable. The flare creates a geometric constraint that prevents the nut from sliding off, establishing an equipotential state where the nut remains securely in place without additional retention mechanisms
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 tool effectively prevents nut slippage and ensures secure connections by creating a uniform flare while removing burs, enhancing the reliability of solar energy installations and other applications.
Implementation Method 1
The force-transmission cylinder has a threaded bore running axially therethrough for receipt of a correspondingly threaded force-transmitting driver
Implementation Method 2
the compression head of the driver is moved towards and into contact with the tubing section, whereby to compress and flatten the end
Implementation Method 3
The deburring rim which moves with the compression head is received inwardly of the tubing section to automatically and simultaneously smooth any burs that are formed at the compressed end
Data Source
AI summary
A compression tool for compressing and flattening one or both ends of a length of corrugated tubing commonly used for making solar installations. A threaded force-transmitting driver is located within a threaded bore of a force-transmission cylinder. A clamp is disposed in surrounding engagement with the corrugated tubing. Tube retaining lips of the clamp are received between an adjacent pair of corrugatings to hold one end of the corrugated tubing in stationary axial alignment with the force-transmitting driver. A rotational force applied to the threaded force-transmitting driver causes the driver to rotate and move through the threaded bore of the force-transmission cylinder. A compression head at the front of the driver is correspondingly moved towards and into contact with the end of the tubing to compress and flatten the end to prevent a nut from sliding off the tubing.