Molded Pipe Joint Gripping Elements With Precise Sintered Teeth
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Solution Overview
Problem
Current methods for producing gripping inserts for pipe joints are costly, complex, and inefficient, with high production costs and equipment wear, and poor dimensional control, limiting the size and accuracy of the parts produced.
Innovation Solution
The use of special metal injection molding (MIM) techniques, specifically the Tundra® Technology, which involves creating a 3D printed mold, injection molding of metal-polymer composites, thermal debinding and sintering in one step, and minimal machining, to produce heavy, dense, and accurately dimensioned gripping elements with low shrinkage rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional metal machining methods are used to produce gripping inserts, then the parts can be manufactured with adequate strength, but the production costs are high, equipment wear is severe, and manufacturing efficiency is low
Solution Approach 1:
The patent changes the physical state and processing parameters by using metal-polymer composite powders instead of solid metal stock, enabling injection molding processing which dramatically improves productivity while reducing equipment wear and manufacturing complexity
Solution Approach 2:
The patent replaces traditional mechanical machining processes with injection molding and sintering processes, substituting mechanical removal of material with a forming process that builds the part directly, thereby improving productivity and reducing equipment wear
2Manufacturing precision
If conventional molding processes are used, then production can be simplified, but dimensional control and accuracy of the gripping elements are poor
Solution Approach 1:
The patent uses metal-polymer composite materials that combine the flowability and molding characteristics of polymers with the strength and dimensional stability of metal particles, enabling both simplified processing and high dimensional control in the final sintered part
Solution Approach 2:
The patent utilizes the phase transition from green state (after injection molding) to sintered state (after thermal processing), where controlled sintering densifies the composite while maintaining precise dimensional control through the polymer binder's protective effect during processing
3Weight of moving object
If heavy gripping elements are produced to increase part size and weight, then the restraint capability is improved, but traditional methods result in high production costs and equipment wear
Solution Approach 1:
The patent changes the processing parameters by using injection molding with metal-polymer composites, which can efficiently produce heavy parts in a single process step, thereby improving productivity and reducing costs while achieving the required part weight for effective gripping
Solution Approach 2:
The patent incorporates metal particles and polymer binder in predetermined ratios and distributions during the injection molding process, pre-forming the heavy gripping elements with optimal material distribution before sintering, which reduces production steps and costs while achieving the required weight and dimensions
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 approach results in high-quality, durable gripping elements with improved dimensional control, reduced production costs and energy consumption, and increased part size capabilities, enabling the production of heavy, accurately dimensioned parts with minimal machining and no deformation, suitable for use in pipe sealing and restraint systems.
Implementation Method 1
The green metal composite article is thermally debound and sintered to produce a hardened gripping element
Data Source
AI summary
A method is shown for manufacturing a hardened gripping element for a sealing and restraint system used for forming a pipe joint in a fluid pipeline. Instead of machining the gripping elements used in the system from a metal stock, a special series of metal injection molding steps are utilized. A metal polymer composite mix is first formed having a metal particulate phase and a polymer phase. A green metal composite article is formed by either extruding the composite mix or molding the composite mix into a metal polymer composite article having at least one gripping surface having a plurality of gripping teeth. The composite article is subjected to thermal debinding and sintering to produce a finished or near finished hardened gripping element.