Induction Connection Sleeve With Centered Heating Elements
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Solution Overview
Problem
Existing induction connection sleeves for plastic pipes face challenges in achieving uniform heating and precise positioning of induction heating elements, leading to limited connection strength and difficulty in production.
Innovation Solution
The design features a sleeve body with coaxially positioned bush-shaped induction heating elements embedded within, surrounded by an internal and external part, allowing precise positioning and uniform heating, with a thermoplastic material composition that ensures only the internal part is fused during heating, maintaining dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If induction heating elements are embedded directly in the sleeve body without surrounding receptacle portions, then the structure is simpler and easier to produce, but the plastic pipe connects to the heating elements only to a limited extent resulting in poor heating uniformity
Solution Approach 1:
The sleeve body is divided into an internal part and an external part that are connected in a materially integral manner. The induction heating elements are embedded in the internal part and surrounded by the external part, creating distinct functional zones that enable both easy production and uniform heating.
Solution Approach 2:
The induction heating elements are nested within the internal part, which is itself nested within the external part of the sleeve body. This nested structure allows the heating elements to be surrounded by the sleeve body while maintaining their embedded configuration, resolving the contradiction between structural simplicity and heating effectiveness.
2Productivity
If induction heating elements are positioned without precise centering in the sleeve body, then the production process is simpler, but the receptacle portions are not heated in a uniform manner
Solution Approach 1:
The induction heating elements are pre-positioned and fixed in the internal part during the injection molding process. This preliminary positioning ensures that when the external part is added, the heating elements are already correctly centered, eliminating the need for subsequent adjustment operations and ensuring uniform heating.
Solution Approach 2:
The positioning of induction heating elements and the formation of the sleeve body are merged into a single injection molding operation. The heating elements are laid up in the molding cavity and the plastics material is injected around them, combining positioning and structure creation in one step, which ensures both productivity and positioning accuracy.
3Device complexity
If the entire sleeve body is heated uniformly, then the heating process is simpler, but the external part deforms due to excessive heat affecting dimensional stability
Solution Approach 1:
The sleeve body is designed with different thermal properties in different regions. The internal part contains the induction heating elements and is intended to be heated, while the external part surrounds it and is designed to remain relatively cool. This local differentiation allows selective heating of only the internal part without deforming the external part, maintaining dimensional stability.
Solution Approach 2:
The internal part acts as an intermediary between the induction heating elements and the external part. It conducts the heat from the heating elements to the plastic pipe connection areas while the external part provides structural support and remains thermally isolated, preventing deformation while allowing the heating process to proceed.
4Strength
If more energy is applied to achieve better connection strength, then the welding quality improves, but the external part deforms due to excessive heat
Solution Approach 1:
The heating energy is localized to the internal part of the sleeve body where the connection needs to be made. The external part is thermally isolated and does not experience the same heat levels. This allows high energy input for strong welding in the connection zone without causing deformation in the external structural part.
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 configuration enhances the production accuracy and strength of the connection, achieving a high degree of strength and tightness in the welded plastic pipes while maintaining the internal part's dimensional stability with reduced energy input.
Implementation Method 1
two bush-shaped induction heating elements which are embedded in the sleeve body and surround the receptacle portions
Data Source
AI summary
A method for producing an induction connection sleeve includes laying up a first induction heating element in a first injection-mold half; laying up a second induction heating element in a second injection-mold half; mutually compressing the first and second injection-mold halves; injecting a thermoplastic plastics material into first and second molding cavities; opening the first and the second injection-mold halves; ejecting an internal part of a sleeve body having induction heating elements from one of the injection-mold halves; laying up the internal part of the sleeve body having the induction heating elements in a third injection-mold half; closing a third molding cavity; injecting a thermoplastic plastics material into the third molding cavity; opening the third molding cavity; and ejecting the finished induction connection sleeve.