Induction Welding of Plastic Pipe Connectors
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Solution Overview
Problem
Existing induction weldable pipe connectors for plastic pipe distribution systems in plumbing systems face inefficiencies in electromagnetic induction welding, particularly due to non-uniform electromagnetic field distribution and weaker welds when the induction coil does not envelop the socket from underneath.
Innovation Solution
The introduction of induction weldable pipe connectors with a solid metal susceptor sleeve enveloping a plastic solder lining, allowing for efficient electromagnetic energy conversion and uniform heating, and the use of electromagnetic induction coil assemblies with semi-tubular shells and dual component induction coils to provide a near uniform electromagnetic field for effective welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an induction coil assembly is placed on the socket from above only, then the coil assembly is easier to install, but the welding strength is weaker compared to enveloping from all sides
Solution Approach 1:
The induction coil assembly is divided into two separate coil sections (first coil section and second coil section) that can be independently positioned. One coil section is placed on the topside of the socket while the other is positioned on the underside, allowing the system to achieve comprehensive envelopment for stronger welding while maintaining relatively simple installation procedures through modular assembly
Solution Approach 2:
The solution transitions from single-sided (one-dimensional approach) coil placement to dual-sided (three-dimensional envelopment) coil arrangement. By adding the underside coil section, the system achieves complete circumferential envelopment of the socket, transforming the welding configuration from partial to comprehensive coverage
2Device complexity
If a non-uniform electromagnetic field is used for induction welding, then the coil assembly design is simpler, but the welding uniformity and strength are reduced
Solution Approach 1:
Different coil sections are strategically positioned at different locations (topside and underside) to create locally optimized electromagnetic field distribution. Each coil section generates a uniform field in its immediate vicinity, and the combination of multiple localized uniform fields results in overall uniform heating and welding across the entire socket interface
Solution Approach 2:
Multiple electromagnetic field sources (first coil section and second coil section) are combined to create a comprehensive uniform field distribution. The individual uniform fields from each coil section merge to provide consistent electromagnetic energy distribution across all surfaces of the socket, ensuring uniform welding quality
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 enhances the efficiency of electromagnetic energy conversion, reduces the size and weight of energy generators, and achieves stronger, more uniform welds by ensuring consistent heating and improved interlocking contact surfaces, enabling the welding of pipes with the same or different materials and diameters.
Implementation Method 1
an electromagnetic induction coil for generating an electromagnetic field for inducing electromagnetic induction in the solid metal susceptor sleeve
Implementation Method 2
The susceptor sleeve becomes sufficiently heated to melt its plastic solder lining
Implementation Method 3
The susceptor sleeve becomes sufficiently heated to melt its plastic solder lining
Data Source
Figure 1
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AI summary
Electromagnetic induction welding of plastic pipe distribution systems including inter alia induction weldable pipe connectors each having at least one induction weldable pipe socket. The induction weldable pipe sockets include a solid metal susceptor sleeve enveloping a plastic solder lining. Electromagnetic induction coil assemblies for clamping on induction weldable pipe sockets.