PEX Tube Expansion Rollers for Faster Leak-Sealed Connections
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Solution Overview
Problem
Existing PEX tubing expansion tools require manual heating to ensure sealing, which is inefficient and time-consuming, especially when not all connections are leaking, and there is a lack of effective methods to identify and seal leaks in tubing systems.
Innovation Solution
A PEX expansion tool with a working element that expands tubing ends using centrifugal force and a method to identify leaks using heated air and thermal detection, along with a pressure testing system to automatically determine sealing status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual heat gun is used on each connection to ensure sealing, then sealing reliability is improved, but time consumption and labor effort increase significantly
Solution Approach 1:
The system uses heated air to automatically identify and seal leaks without requiring manual intervention on each connection. The heated air flows through the tubing system and automatically seals leaks based on thermal detection, allowing the system to serve itself rather than requiring manual heat gun application at each connection point.
Solution Approach 2:
The patent replaces the manual mechanical heat gun operation with an automated heated air delivery system. Instead of manually applying heat at each connection, the system uses a centralized heated air source that automatically identifies and seals leaks through thermal detection and automated air delivery, substituting manual mechanical operation with an automated thermal system.
2Reliability
If manual heat gun is applied to all connections, then all potential leaks are sealed, but effort is wasted on connections that are already properly sealed
Solution Approach 1:
The system incorporates thermal detection that provides feedback on the sealing status of connections. By monitoring thermal characteristics, the system can identify which connections actually have leaks and require sealing, versus those that are already properly sealed. This feedback mechanism allows the system to operate efficiently by targeting only the connections that need attention.
Solution Approach 2:
The system applies heating and sealing actions locally and selectively to specific connections that are identified as having leaks, rather than uniformly treating all connections. The heated air is directed to specific problem areas based on thermal detection feedback, providing localized quality control and avoiding unnecessary operations on already-sealed connections.
3Ease of manufacture
If traditional expansion tools are used, then tubing can be expanded for fittings, but the process lacks automated leak identification and sealing capabilities
Solution Approach 1:
The patent combines the tubing expansion function with automated leak identification and sealing capabilities into a single integrated system. The expansion tool is merged with thermal detection sensors and heated air delivery mechanisms, allowing the system to perform expansion, detect leaks, and seal connections in an automated sequence without requiring separate manual operations.
Solution Approach 2:
The system performs multiple functions: tubing expansion, thermal-based leak detection, and automated leak sealing. By integrating these diverse functions into a single tool, the system achieves multi-functionality that eliminates the need for separate manual operations for each task, significantly improving automation extent while maintaining ease of manufacture.
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 tool efficiently expands PEX tubing for secure fittings and automatically identifies and seals leaks, reducing time and effort in plumbing applications.
Implementation Method 1
the rollers are engageable with an inner circumference of the tube when the main body rotates about the axis to expand the end of the tube by centrifugal force
Implementation Method 2
A PEX expansion tool with a working element that expands tubing ends using centrifugal force and a method to identify leaks using heated air and thermal detection
Implementation Method 3
The PEX tube elastically recovers around the fitting to form a tight connection
Data Source
Figure 1
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Figure 4
AI summary
A working element operable to expand an end of a tube includes a main body configured to rotate about an axis, a plurality of roller supports movably coupled to the main body, the roller supports movable relative to the main body between a retracted position and an expanded position, and a plurality of rollers coupled to the roller supports such that a distance between a first roller of the plurality of rollers and a second roller of the plurality of rollers increases when the roller supports move toward the expanded position. The rollers are configured to be inserted into the end of the tube when the roller supports are in the retracted position, and the rollers are engageable with an inner circumference of the tube when the main body rotates about the axis to expand the end of the tube.