Flangeless Conduit Coupler for Uniform Bore Leak-Resistant Joints
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Solution Overview
Problem
Existing industrial hoses and pipes require flanges for coupling, which can disrupt the uniform internal diameter and create potential leak points, especially when bolted together, leading to inefficiencies in conveying liquids or gases.
Innovation Solution
A flangeless coupler comprising a perforated metallic element encapsulated in a plastic or polymeric material, overmolded to form a robust and uniform joint that maintains a consistent internal diameter by being heated to fuse within the conduit ends, with optional tapered ends and a locating ridge for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flanges are used to couple conduits, then the coupling strength and reliability are improved, but the internal diameter uniformity deteriorates and leak points are created
Solution Approach 1:
The invention extracts and eliminates the flange component from the coupling system. Instead of using traditional flanges that protrude from the conduit ends, the coupler is inserted inside the conduits and fused internally, removing the external flange structure that disrupts internal diameter uniformity and creates leak points.
Solution Approach 2:
The coupler is nested inside the conduit ends rather than being mounted externally. The internal coupling structure is inserted within the conduits and fused to their inner surfaces, creating a nested configuration that maintains the external contour and internal diameter of the conduits while providing secure coupling.
2Strength
If flanges with bolts are used for coupling, then the connection strength is improved, but the complexity of the coupling structure increases
Solution Approach 1:
The invention merges multiple functions into a single integrated coupler component. The coupler combines coupling, sealing, and strengthening functions in one piece that is fused internally, eliminating the need for separate flanges, gaskets, and multiple bolts that characterize traditional coupling systems.
Solution Approach 2:
The invention replaces the mechanical bolted flange system with a thermal fusion bonding system. Instead of using external mechanical fasteners (bolts and nuts), the coupler is thermally fused to the conduit ends, creating a permanent bond through material fusion rather than mechanical fastening.
3Ease of operation
If flanges are used for coupling, then the ease of assembly is improved, but the potential for leaks increases
Solution Approach 1:
The invention replaces the mechanical flange-and-bolt system with a thermal fusion system. The coupler is heated to melt and fuse with the conduit ends, creating a seamless, monolithic joint that eliminates the flange interfaces where leaks typically occur in mechanical coupling systems.
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 solution provides a secure, leak-resistant, and uniform internal diameter connection without the need for flanges, capable of withstanding various pressures and ensuring consistent flow, while maintaining the structural integrity of the conduits.
Implementation Method 1
the joint is heated to fuse the coupler inside the hose/pipe ends
Implementation Method 2
heated to fuse the coupler inside the conduit ends
Data Source
AI summary
A flangeless conduit coupler for joining the ends of two conduits together includes a metallic element and a polymeric element. The metallic element includes a hollow cylindrical element having a plurality of perforations established therethrough. The polymeric element is overmolded at the metallic element so that the metallic element is encapsulated by the polymeric element with the polymeric element present within the perforations of the metallic element. The coupler is disposed in flared ends of opposing conduits and is fused therein to join the conduits and seal the conduit joint. The coupler has an inside diameter that corresponds with the inside diameter of the conduits remote from the flared ends.