Extruded Compression Collar with Positioning Tabs for Leak-Free Fits
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Solution Overview
Problem
Existing methods for manufacturing compression collars for cold-expansion tubing connections are inefficient, requiring time-consuming and costly processes that generate significant waste, such as reaming and warming, to create positioning stops and expand the collars.
Innovation Solution
The method involves extruding cold-expansion material into tubes with internal ridges that are trimmed to form positioning tabs, allowing for rapid and precise manufacturing of compression collars with reduced material waste, enabling simultaneous expansion and contraction for a secure seal between piping and fittings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the inner diameter of the extruded tube is machined out to create a stop edge, then the compression collar can be positioned during installation, but the manufacturing time increases and large amount of scrap material is generated
Solution Approach 1:
The stop edge is formed during the extrusion process itself, before the tube is cut to length. The extrusion die is designed with a specific geometry that creates the stop edge as part of the initial forming operation, eliminating the need for subsequent machining operations to create this positioning feature.
Solution Approach 2:
The inner diameter of the extruded tube varies along its length, with one end having a smaller diameter than the other. This gradient in diameter is created during extrusion and provides the stop edge function without requiring material removal. The parameter change in inner diameter is built into the extrusion process rather than applied afterward.
2Ease of operation
If the inner diameter of the extruded tube is machined out to create a stop edge, then the compression collar can be positioned during installation, but the amount of scrap material increases
Solution Approach 1:
The stop edge is formed during the extrusion process itself, before the tube is cut to length. The extrusion die is designed with a specific geometry that creates the stop edge as part of the initial forming operation, eliminating the need for subsequent machining operations to create this positioning feature.
Solution Approach 2:
The inner diameter of the extruded tube varies along its length, with one end having a smaller diameter than the other. This gradient in diameter is created during extrusion and provides the stop edge function without requiring material removal. The parameter change in inner diameter is built into the extrusion process rather than applied afterward.
3Manufacturing precision
If the entire inner diameter of the tube is smaller than the desired finished dimension, then the stop edge can be created, but the manufacturing complexity increases due to additional machining operations
Solution Approach 1:
The stop edge is formed during the extrusion process itself, before the tube is cut to length. The extrusion die is designed with a specific geometry that creates the stop edge as part of the initial forming operation, eliminating the need for subsequent machining operations to create this positioning feature.
Solution Approach 2:
The inner diameter of the extruded tube varies along its length, with one end having a smaller diameter than the other. This gradient in diameter is created during extrusion and provides the stop edge function without requiring material removal. The parameter change in inner diameter is built into the extrusion process rather than applied afterward.
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
This approach reduces manufacturing time and costs while enhancing the strength and reliability of the interference fit, minimizing waste and ensuring a long-lasting, leak-free connection.
Implementation Method 1
manufacture a hollow, tubular material and imbue it with shape memory properties (e.g., through cross-linking, irradiation, steam, etc.) such that when the tubing is stretched or deformed, the tubing returns to the shape set in its memory during the manufacturing process
Implementation Method 2
The elastic forces within the cold-expansion tubing material can be applied to any object that interferes with the cold-expansion tubing returning to its original shape
Implementation Method 3
Making compression collars through extrusion of the plastic material in a tubular form has been disclosed in the prior art
Data Source
AI summary
Disclosed are systems and methods for manufacturing compression collars for reinforcing sealed connections between a length of piping and a plumbing fitting. Specifically, compression collars and related methods of making include extruding a hollow tube having one or more ridges which are then partially removed or trimmed to provide positioning tabs on one end of the compression collar. The compression collars can be cut to the desired length from the extruded hollow tube. In this way, compression collars with features for enhancing the strength and reliability of an interference fit, as well as their ease of use, can be manufactured rapidly with little material waste through modifications to the extrusion process.