Electromagnetic Bond Welding Thermoplastic Pipe Joints
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Solution Overview
Problem
Conventional copper plumbing systems require skilled labor and are hazardous due to soldering processes, while existing thermoplastic solutions lack efficient on-site joining methods.
Innovation Solution
Electromagnetic bond welding of thermoplastic pipes using a fusion pipe ring and socket with a susceptor layer, heated by an induction coil to form a reliable joint, eliminating the need for soldering and reducing manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper pipe systems are used with conventional soldering, then reliable joints can be achieved, but the process requires skilled labor and poses fire hazards and fume release
Solution Approach 1:
The patent replaces the thermal soldering process with an electromagnetic induction welding system. An induction coil generates an electromagnetic field that induces eddy currents in a susceptor layer, generating heat through resistive heating (Joule heating) to melt and fuse the thermoplastic materials. This substitution eliminates open flames and fume generation while maintaining joint reliability through controlled electromagnetic heating.
Solution Approach 2:
The invention changes the heating method from conventional thermal conduction (soldering) to electromagnetic induction heating. By controlling the electromagnetic field parameters (frequency, power, duration), the system achieves precise temperature control for melting thermoplastic materials, eliminating the need for skilled manual soldering while ensuring reliable joints.
2Reliability
If copper pipe systems are used with conventional soldering, then joints can be formed, but the process is manually intensive and requires skilled operators
Solution Approach 1:
The patent replaces manual soldering operations with an automated electromagnetic induction system. The induction coil, susceptor layer, and controlled heating process eliminate the need for skilled manual manipulation of torches and solder, making the joint formation process accessible to unskilled workers while maintaining high reliability.
Solution Approach 2:
The susceptor layer automatically generates heat when exposed to the electromagnetic field, eliminating the need for external heat application. The system self-regulates the heating process through electromagnetic induction, reducing manual intervention and skill requirements while ensuring consistent joint formation.
3Strength
If thermoplastic pipe materials are used, then lightweight and chemically resistant systems are achieved, but efficient on-site joining methods are lacking
Solution Approach 1:
The patent introduces electromagnetic induction welding as an efficient on-site joining method for thermoplastic pipes. The induction coil and susceptor layer system enables rapid heating and fusion of thermoplastic materials at the installation site, eliminating the need for complex manual joining procedures while preserving the chemical resistance and lightweight advantages of thermoplastics.
Solution Approach 2:
The invention utilizes the phase transition of thermoplastic materials from solid to molten state through electromagnetic heating. The susceptor layer converts electromagnetic energy to heat, melting the thermoplastic pipe and fitting materials, which are then fused together and cooled to form a strong, leak-proof joint, providing an efficient on-site joining method.
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
Facilitates quick, reliable, and safe joining of thermoplastic pipes with reduced manual effort and eliminates the hazards associated with soldering, enhancing the efficiency and safety of plumbing installations.
Implementation Method 1
An induction coil is placed around the fusion pipe socket. Radiated electromagnetic energy heats the susceptor layer to melt at least a portion of the susceptor layer, at least a portion of the fusion pipe ring, at least a portion of the fusion pipe socket, and at least a portion of the pipe.
Implementation Method 2
Radiated electromagnetic energy heats the susceptor layer to melt at least a portion of the susceptor layer
Implementation Method 3
The fusion pipe ring is further screwed in to compress the molten material. The joint is then cooled to solidify the molten material.
Data Source
AI summary
A thermoplastic pipe distribution system is assembled by electromagnetic bond welding of a thermoplastic pipe to a thermoplastic fusion pipe joint assembly comprising a threaded fusion pipe ring, a threaded fusion pipe socket, and a susceptor layer between the fusion pipe ring and the fusion pipe socket. The fusion pipe ring is screwed into the fusion pipe socket, and the pipe is inserted into the fusion pipe ring. An induction coil is placed around the fusion pipe socket. Radiated electromagnetic energy heats the susceptor layer to melt at least a portion of the susceptor layer, at least a portion of the fusion pipe ring, at least a portion of the fusion pipe socket, and at least a portion of the pipe. The fusion pipe ring is further screwed in to compress the molten material. The joint is then cooled to solidify the molten material.