Modular Thermoplastic Fittings Welded End Faces
Solution Overview
Problem
Existing plastic fittings for large-diameter pipelines are costly for small-batch production and do not meet requirements for compressive strength and surface integrity due to complex injection molding processes and inadequate weld seam design.
Innovation Solution
A modular fitting system using weldable thermoplastic materials with end surfaces perpendicular to the center axis, allowing for welding only around the circumference, which enhances compressive strength and reduces production costs by eliminating the need for expensive injection molds and minimizing internal weld seam interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to produce fittings, then large numbers of parts can be produced at low cost per part, but the mold cost is very high and not affordable for small-batch production
Solution Approach 1:
The fitting is divided into multiple separately moldable components that can be produced independently and then assembled through welding. This allows each component to be produced with simpler, less expensive molds while maintaining the functionality of the complete fitting assembly.
2Ease of manufacture
If pipe segments are welded together to form fittings, then production cost for small batches is reduced, but the weld seams in corners are exposed to high loading and do not meet nominal pressure requirements
Solution Approach 1:
The wall thickness is increased specifically in the region where the separating location and seam between elements occur, providing localized reinforcement at the critical stress point while maintaining standard wall thickness elsewhere in the fitting components.
3Ease of manufacture
If weld seams run longitudinally along the circumference, then pipe sections can be connected, but the seams are exposed to extremely high loading and would not meet requirements for nominal pressures
Solution Approach 1:
Instead of welding pipe segments longitudinally along the circumference, the invention inverts the approach by welding elements together at their end surfaces with end surfaces running at right angles to the center axis, creating circumferential weld seams that are perpendicular to the flow direction and better positioned to withstand pressure loads.
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 modular design enables cost-effective production of fittings with high compressive strength, suitable for small-batch production, and minimizes internal weld seam interference, allowing for efficient installation and reduced maintenance in pipeline systems.
Implementation Method 1
the elements are welded to one another exclusively on the end surfaces
Data Source
AI summary
A fitting (1) of weldable, thermoplastic material of a modular structure, comprising a number of elements (2, 3, 9, 10, 11, 12), at least one main element (2, 9) and at least one connecting element (3, 10, 11, 12), characterized in that the elements (2, 3, 9, 10, 11, 12) have end faces (4, 5) at right angles to the center axis (8), and the elements (2, 3, 9, 10, 11, 12) are welded to one another exclusively at the end faces (4, 5).