Heated Polymer Coupling Element for Low-Temperature Pipe Bonding
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Solution Overview
Problem
Existing coupling technologies rely on solvent-based adhesives, which pose environmental and health hazards, and require high energy for thermal joining methods that can damage substrate materials.
Innovation Solution
A coupling element featuring a transition polymer bonding material with a heating element that melts at a lower temperature than the substrate, allowing for efficient adhesion without substrate melting, and optionally includes a foaming agent for gap closure, using energy-efficient heating methods like Joule effect or exothermic reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based adhesives are used for connecting pipes, then the coupling process can be simplified, but environmental and health hazards increase due to evaporating chemical substances
Solution Approach 1:
The patent removes the harmful solvent component from the adhesive system by using hot melt adhesives that are applied in a molten state and solidify upon cooling, eliminating the need for solvent evaporation while maintaining effective bonding capability
Solution Approach 2:
The patent changes the physical state parameter of the adhesive from solvent-based liquid to thermoplastic solid, utilizing temperature-controlled phase transitions to achieve application and bonding without harmful chemical solvents
2Strength
If high temperature thermal joining methods are used to achieve strong bonding, then bonding strength increases, but substrate materials may be damaged
Solution Approach 1:
The patent applies heating elements only at the bonding interface between the coupling element and substrate, creating localized heat zones that melt the thermoplastic adhesive without heating the entire substrate to damaging temperatures
Solution Approach 2:
The patent introduces a thermoplastic adhesive layer as an intermediary material between the coupling element and substrate, which melts at controlled temperatures to enable bonding while protecting the substrate from direct exposure to high temperatures
3Manufacturing precision
If foaming agents are used to compensate for diameter tolerances, then gap closure improves, but the complexity of the bonding material increases
Solution Approach 1:
The patent combines the foaming agent functionality with the thermoplastic adhesive material itself, creating an integrated bonding material that simultaneously provides adhesion and gap-filling capabilities through controlled foam expansion during the bonding process
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 solution eliminates the need for solvent-based adhesives, reduces energy consumption, and ensures strong bonding without damaging substrate materials, while also addressing diameter tolerances and circularity variations in pipe connections.
Implementation Method 1
The heating element will receive the energy (electrical, magnetic field, exotermic reaction initiation...) and heat (by joule effect, exotermic reaction...)
Implementation Method 2
The heating element will receive the energy (electrical, magnetic field, exotermic reaction initiation...) and heat (by joule effect, exotermic reaction...)
Implementation Method 3
the bonding material being weldable at a melting temperature... heat the bonding material at a temperature equal to or greater than the melting temperature
Implementation Method 4
Another foaming agent is used in KR 20130004866 in which a foam sheet is foamed while expanding in volume. The water tightness is ensured by pressure generated by the expanded foam sheet.
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
The present invention proposes a coupling element comprising a coupling body (12) having a first joining surface (13), said coupling body (12) comprising a bonding material being weldable at a melting temperature. At least one heating element (50) is provided to heat the bonding material at a temperature equal to or greater than the melting temperature, the at least one heating element being encapsulated with the bonding material or provided at the first joining surface. The bonding material being a transition polymer. -The bonding material is provided with a foaming agent, preferably within the bonding material, wherein the foaming agent has an activation temperature so that the foaming agent can be activated by the heat generated by the heating element in the bonding material during the molten phase. The present invention also proposes a coupling assembly comprising such a coupling element and a first substrate assembled on the first joining surface, and a method of obtaining a such a coupling assembly comprising the steps of adjoining the first substrate on the coupling element and providing energy to the at least one heating element to cause the heating of the bonding material up to the melting temperature.