Electrofusion Composite Pipe Coupler With Axial Load Transfer
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Solution Overview
Problem
Existing electrofusion methods for joining thermoplastic pipes are limited by their inability to join thermoset pipes, unbonded reinforced thermoplastic pipes, and have low shear strength and burst pressure capabilities, particularly under axial loads.
Innovation Solution
A composite electrofusion pipe coupler system using a coupler housing with a wire, electrodes, gripping wedges, and nuts that applies mechanical and electrical forces to bond thermoset or thermoplastic pipes, incorporating materials like nickel, high-density polyethylene, and brass, and featuring a fiberglass or carbon fiber composite insert to enhance strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing electrofusion methods are used to join thermoplastic pipes, then the joining process is simple and quick, but the joint has low shear strength and low burst pressure capability
Solution Approach 1:
The coupler employs a composite structure combining metal components (housing, electrodes, gripping wedges) with continuous fiber reinforced polymer materials. This composite construction provides both the speed of electrofusion bonding and the structural strength to withstand high burst pressures and shear loads, resolving the contradiction between quick joining and joint strength.
Solution Approach 2:
The invention merges two joining mechanisms: electrofusion bonding for rapid connection and mechanical gripping through wedges for strength enhancement. The gripping wedges engage with the pipe externally while the electrofusion process bonds internally, creating a dual-mechanism joint that achieves both quick installation and high structural integrity.
2Device complexity
If existing electrofusion methods are used, then the equipment is simple, but the joint cannot withstand high axial loads
Solution Approach 1:
The gripping wedges are pre-positioned within the coupler housing before the joining process. As the electrofusion bonding occurs, the wedges are already in place to engage with the pipe externally, providing immediate axial load capacity once the pipe is inserted, rather than requiring additional post-joining steps to enhance load-bearing capability.
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 system provides a robust and leak-proof joint that withstands mechanical loads and burst pressures, enabling the joining of various composite pipes without elastomeric seals, while allowing for the transfer of axial loads through mechanical grips, thus improving the reliability and performance of pipe connections.
Implementation Method 1
a wire configured and disposed within the housing; a plurality of electrodes affixed to the coupler housing and in electrical contact with the wire
Implementation Method 2
a plurality of gripping wedges affixed to the coupler housing, wherein each gripping wedge extends from the coupler housing; wherein the second nut applies gripping force from the wedges to a connected pipe
Data Source
AI summary
Disclosed embodiments provide an electrofusion pipe coupler with mechanical support. The electrofusion pipe coupler comprises a coupler housing. A wire is configured and disposed within the housing. Electrodes are affixed to the coupler housing and in electrical contact with the wire. A threaded pattern is formed in an outer surface of the coupler housing. Gripping wedges are affixed to the coupler housing. Each gripping wedge extends from the coupler housing. A nut is attached to the coupler housing, engaging with the threaded pattern, and compressing the wedges against the connecting pipes. This serves to provide axial load transfer from the connecting pipes to the coupler housing via the wedges, thereby providing improved mechanical stability for such pipe assemblies.