Multi-Diameter PEX Expander Head to Eliminate Toolhead Switching

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Solution Overview

Problem

The existing PEX tubing expansion tools require multiple toolheads for different diameters, leading to inefficiencies in switching between sizes, increased time spent on installation, and potential for toolheads to be misplaced or contaminated in construction environments, with no significant advancements in nearly a decade.

Innovation Solution

A single toolhead designed to expand multiple standard size diameters of PEX tubing, featuring a 360-degree jaw section with multiple lands and ramps, allowing for sequential expansion of ½ inch, ¾ inch, and 1 inch tubing without the need to remove and replace toolheads, and can be integrated or threaded onto existing expansion tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple toolheads are used for different PEX tubing diameters, then each diameter can be expanded with the appropriate specialized toolhead, but the device complexity increases and switching between sizes becomes time-consuming

Engineering Contradiction:

Improveability to expand multiple diametersVSAvoidnumber of toolheads required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single toolhead that can expand multiple different diameters of PEX tubing. The toolhead includes a jaw section with multiple lands of different diameters, allowing it to accommodate and expand various tubing sizes (e.g., 1/2 inch, 3/4 inch, 1 inch) without requiring separate specialized toolheads for each diameter.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent applies segmentation by dividing the jaw section into multiple lands, where each land has a different diameter corresponding to a specific tubing size. This segmentation allows the single toolhead to provide multiple expansion capabilities through distinct functional zones on the same component.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple toolheads are used for different PEX tubing diameters, then each size can be properly expanded, but the loss of time increases due to switching between toolheads during installation

Engineering Contradiction:

Improveability to expand multiple diametersVSAvoidswitching time between toolheads

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The universal toolhead design eliminates the need to switch between multiple specialized toolheads during installation. By incorporating multiple lands of different diameters in a single toolhead, the installer can expand various tubing sizes sequentially without removing and replacing toolheads, thereby reducing time loss.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple toolheads are used for different PEX tubing diameters, then each diameter can be expanded with proper fit, but the risk of contamination and misplacement increases in construction environments

Engineering Contradiction:

Improveability to expand multiple diametersVSAvoidcontamination and misplacement risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The single universal toolhead reduces the number of components that can be misplaced or contaminated. Instead of managing multiple separate toolheads that must be kept organized and clean, the installer uses one multi-functional toolhead, thereby reducing the harmful factors associated with having multiple separate tools in the construction environment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 streamlines the expansion process by eliminating the need for multiple toolheads, reducing switching time, minimizing contamination risks, and enhancing productivity in plumbing installations by allowing a single toolhead to handle various diameters, thus improving efficiency and reducing the burden of handling multiple toolheads.

Implementation Method 1

Both manual and powered expansion tools use a cone-shaped wedge to expand the jaw section between an unexpanded position and an expanded position

Methodology Applied

Scientific EffectMechanical expansion: Mechanical Force

Implementation Method 2

retaining the connector in the expanded portion until a natural resiliency of the PEX tubing causes the expanded portion to shrink

Methodology Applied

Scientific EffectElastic recovery: Elastic Recovery

Data Source

PatentUS11110646B2PEX tubing expander head

Publication Date: 2021.09.07 BROCHMAN INNOVATIONS LLC

AI summary

An expansion toolhead configured to enable the expansion of multiple different sized diameters of cross-linked polyethylene (PEX) tubing with a single expansion toolhead. The expansion toolhead including a cap operably coupled to an expansion tool, and a plurality of jaws forming a 360 degree jaw section operably coupled to the cap, each of the plurality of jaws including an expansion tool interface portion forming a conical recess enabling a cone-shaped wedge of the expansion tool to move the jaw section between an unexpanded position and an expanded position, and a PEX tubing interface portion having a distal end, a proximal end and a plurality of lands positioned therebetween configured to form a corresponding plurality of substantially uniform diameter portions of the jaw section sequentially increasing in diameter between the distal end and the proximal end for the expansion of multiple different standard sized diameters of VEX tubing.