Insulated Socket Rims for Induction-Welded Pipe Connectors
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Solution Overview
Problem
Current electromagnetic induction welding methods for plastic pipes face challenges in ensuring a sealed and efficient connection, particularly with multi-layer pipes, as melted solder can flow inwardly, reducing the pipe's internal diameter and affecting flow, and existing solutions lack effective insulation and user safety features.
Innovation Solution
The proposed solution involves an induction weldable pipe connector with a three-component construction: a tubular induction weldable mounting with a solid ferromagnetic metal susceptor sleeve, a thermoplastic solder lining, and a thermally insulated cover with ventilation holes, which ensures the melted solder expands and builds pressure for a sealed connection while maintaining user safety and allowing for multi-layer pipe compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electromagnetic induction welding is used to connect plastic pipes, then welding speed and efficiency are improved, but melted solder may flow inwardly reducing pipe internal diameter and affecting flow
Solution Approach 1:
The harmful element (melted solder flow) is extracted from the system by introducing a solder flow barrier that prevents it from entering the pipe lumen, while maintaining the beneficial induction welding process
Solution Approach 2:
A solder flow barrier acts as an intermediary element between the solder lining and pipe lumen, allowing the welding process to proceed while blocking the harmful flow of melted solder into the pipe
2Reliability
If solder lining is melted to create sealed connection, then sealing efficiency is improved, but pressure buildup may cause solder to flow radially inward
Solution Approach 1:
The pressure buildup that would normally cause harmful solder flow is converted into a beneficial force by the solder flow barrier, which uses this pressure to ensure complete sealing while preventing inward flow
Solution Approach 2:
The solder flow barrier serves as a mediator that manages the pressure buildup from melted solder, directing it to seal the connection without allowing it to flow into the pipe lumen
3Adaptability or versatility
If induction weldable pipe connector is used for multi-layer pipes, then versatility is improved, but complexity of construction increases
Solution Approach 1:
The pipe connector is designed with universal features including a solder flow barrier and adaptable socket configuration that enable it to work with both single-layer and multi-layer pipes, reducing the need for different connector types
4Reliability
If solder lining is expanded upon melting to seal connection, then sealing is improved, but internal pipe diameter is reduced
Solution Approach 1:
The solder flow barrier extracts or removes the excess melted solder from the pipe lumen before it can reduce the internal diameter, allowing the solder lining to expand for sealing without compromising pipe flow capacity
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 design enhances the sealing efficiency by trapping the melted solder, ensuring a strong and leak-proof joint, while the ventilation holes and thermally insulated cover provide user safety and visual process indication, suitable for various connection types including multi-layer pipes.
Implementation Method 1
application of electromagnetic induction energy to the induction welding mounting melts the solder lining
Implementation Method 2
The susceptor sleeve is in intimate contact with the external solder lining surface for heating same during an electromagnetic induction welding operation
Implementation Method 3
application of electromagnetic induction energy to the induction welding mounting melts the solder lining which leads to its expansion. The increased volume of melted solder lining compared to its initial volume of unmelted solder lining leads to pressure buildup
Implementation Method 4
The cover is spaced apart from the induction weldable mounting thereby providing air insulation therebetween for ensuring the cover is only marginally heated by the susceptor sleeve during an electromagnetic induction welding operation
Data Source
Figure 1
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AI summary
Induction Weldable Pipe Connectors (IWPCs) (400) for electromagnetic induction welding with at least one plastic pipe (30). IWPCs (400) include a tubular induction weldable mounting (401) having an opposite pair of induction weldable sockets (404A, 404B), a tubular cover (406) externally mounted on the induction weldable mounting (401), and a tubular pipe tang (407) internally disposed in one induction weldable socket (404A, 404B) for destining an induction weldable socket (404A, 404B) as an induction weldable pipe socket (408A, 408B) for forced sliding insertion of a pipe end (31) thereinto. The cover (406) includes an opposite pair of thermally insulated induction weldable socket mouth rims (426A, 426B) for entrapping melted solder lining (412) inside the induction weldable mounting (401) during an electromagnetic induction welding operation, thereby ensuring improved welding.