Plastic Pipe Connection with Resistance Wire Pre-Assembly
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Solution Overview
Problem
Current methods for joining plastic pipe elements, such as heat-fusion, electrically weldable, and butt welding, are costly, time-consuming, require skilled labor, and are limited by specific diameter ranges, atmospheric conditions, and result in tube wastage and complex overhead welding processes.
Innovation Solution
An electrically weldable connection device featuring a resistance wire wound on the pipe element's surface, with a clamp to secure the wire and a welding indicator for validation, allowing pre-assembly and on-site connection without permanent welding, enabling connections across various diameters and thicknesses without reducing the pipe section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrically weldable joining with embedded resistance is used, then joining can be performed for intermediate diameters (63-250 mm), but the process becomes extremely slow (20-30 minutes) and requires skilled labor for precise tube preparation
Solution Approach 1:
The invention replaces the embedded resistance heating system with an external induction heating system. Instead of using Joule heating from embedded resistance wires that require long heating times, the patent uses electromagnetic induction to heat the pipe externally, dramatically reducing heating time from 20-30 minutes to just a few minutes while maintaining the ability to join intermediate diameter pipes
Solution Approach 2:
The invention extracts the resistance heating element from inside the pipe structure and replaces it with an external induction heating mechanism. The embedded resistance wires are removed and replaced by an external induction heater that couples electromagnetically with the pipe material, eliminating the need for internal heating elements and long heating cycles
2Manufacturing precision
If thorough tube preparation (scraping rust, etc.) is performed to prevent tolerance differences, then joining precision is improved, but labor cost and time increase significantly
Solution Approach 1:
The invention changes the heating parameter from low-temperature gradual heating (embedded resistance) to high-temperature rapid induction heating. This parameter change allows the heating process to be so rapid that preliminary tube preparation becomes less critical, as the quick heating cycle minimizes the time for tolerance variations to develop while still achieving proper fusion
Solution Approach 2:
The invention eliminates the need for preliminary tube preparation actions (scraping, cleaning, etc.) by using induction heating's rapid heating capability. The pre-heating and preparation steps that were previously necessary to ensure proper fit and tolerance are rendered unnecessary because the rapid induction heating process compensates for minor variations without requiring extensive pre-processing
3Adaptability or versatility
If butt welding with hydraulic units and special clamps is used for large diameters, then joining capability is achieved, but the process becomes significantly slower (40-120 minutes) and requires moving heavy equipment
Solution Approach 1:
The invention replaces the mechanical hydraulic heating and pressing system with an electromagnetic induction heating system combined with a simpler clamping mechanism. Instead of using heavy hydraulic units that require 40-120 minutes for large diameter pipes, the induction heating system rapidly heats the pipe ends while a straightforward clamp maintains positioning, reducing the joining time dramatically while maintaining capability for large diameter pipes
Solution Approach 2:
The invention replaces the complex hydraulic heating and pressing system with an induction heating field that penetrates the pipe material directly. The hydraulic pressure system is simplified to a basic clamping mechanism that holds the pipe ends together during the rapid induction heating process, eliminating the need for complex hydraulic control systems and heavy equipment
4Adaptability or versatility
If heat-fusion socket joining with matrices is used, then joining is achieved for specific diameters (20-125 mm), but equipment cost, maintenance requirements, and workbench requirements increase
Solution Approach 1:
The invention replaces the mechanical matrix-based heat-fusion system with an induction heating system. Instead of using physical heating matrices that require precise temperature control, maintenance, and workbench mounting, the patent uses electromagnetic induction to heat the pipe ends directly through electromagnetic coupling, eliminating the complex matrix equipment and its associated maintenance requirements
Solution Approach 2:
The invention creates a universal joining system that can handle various diameter ranges (20-250 mm and beyond) with a single induction heating device. The induction heater can be adjusted to work with different pipe sizes without requiring changes to heating matrices or specialized equipment, providing multi-functionality across a wide diameter range that eliminates the need for multiple specialized joining systems
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 reduces installation time, eliminates the need for skilled labor, minimizes equipment costs, prevents tube wastage, and allows for a wide range of fittings, ensuring a safer, more reliable, and efficient connection process.
Implementation Method 1
the melting temperature is reached as a result of an electrical resistance that is embedded in an electrically weldable fitting, is often used. The terminals of the welding connector of the fitting are connected to the cables of an electric welding unit and the current generated by the machine heats the resistance by Joule effect.
Data Source
AI summary
A connection device for plastic pipe elements (1) which allows performing pre-assembly and being finally assembled without requiring skilled labor, having a pipe element (1) with at least one end, a plastic connection element (2) which is connected to an outer surface of the pipe element (1) through the end, which has a resistance wire (3) wound on the outer surface of the pipe element (1) itself.