Pipe Manifold Welding Layout to Prevent Corrosion and Thread Damage
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Solution Overview
Problem
Current pipe distribution systems face challenges such as high production and assembly costs, potential for unauthorized component replacement, and issues with galvanic corrosion and cold solder joints, which affect the reliability and longevity of heating and cooling systems.
Innovation Solution
A pipe distribution system design featuring a main pipe with widened areas for functional units, eliminating necks and allowing for secure fusion of components via welding, and a method for producing threads on pipe ends to enhance fluid flow regulation and prevent unauthorized component exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional units are screwed into the main pipe with high tightening torque to prevent loosening, then connection reliability is improved, but thread damage and sealant damage occur
Solution Approach 1:
The connection structure is divided into multiple components: a collar with external thread that screws onto the main pipe, and a functional unit with internal thread that screws onto the collar. This segmentation distributes the tightening torque across two separate thread connections, preventing damage to either individual thread while maintaining secure attachment.
Solution Approach 2:
The collar acts as an intermediary component between the main pipe and the functional unit. It provides a separate threading interface that mediates the connection, allowing the functional unit to be securely attached without directly threading into the main pipe, thereby protecting the main pipe's thread integrity.
2Adaptability or versatility
If collars with threads are attached to the main pipe to enable functional unit installation, then component installation capability is improved, but production costs and assembly costs increase
Solution Approach 1:
The collar is designed as a universal component that can be attached to the main pipe once and then accept multiple different functional units (valves, flow indicators, thermostats). This multi-functionality allows a single collar design to support various components, reducing the need for custom-threaded main pipes for each functional unit type.
Solution Approach 2:
The collar is pre-attached to the main pipe during manufacturing, preparing the installation site in advance. This preliminary action enables functional units to be easily installed by end-users or maintenance personnel without requiring complex threading operations on the main pipe itself, thereby simplifying both production and assembly processes.
3Adaptability or versatility
If different metals and alloys are used in soldered connections, then material selection flexibility is improved, but galvanic corrosion occurs
Solution Approach 1:
The connection method is replaced from soldering (which involves different metals and galvanic corrosion risks) to mechanical threading and fusion welding. The collar provides a mechanical thread-based connection, and the functional unit is subsequently fusion-welded to the collar, eliminating the need for solder joints between dissimilar metals and thus preventing galvanic corrosion.
4Ease of operation
If soldered connections are used to join functional units, then assembly flexibility is improved, but cold solder joints and mechanical load resistance deteriorate
Solution Approach 1:
The soldered joint is replaced with a mechanical thread connection via the collar followed by fusion welding. The threaded collar provides immediate mechanical strength and load resistance, while the subsequent fusion welding of the functional unit to the collar creates a permanent, high-strength bond that can withstand mechanical loads and vibrations without cold joint failures.
Solution Approach 2:
The connection method transitions from low-strength solder joints to high-strength mechanical threading and fusion welding. This parameter change in connection strength and rigidity ensures that the functional units remain securely attached under various mechanical stresses, eliminating the reliability issues associated with cold solder joints.
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 design improves fluid flow regulation, reduces production and assembly costs, prevents unauthorized component changes, and minimizes corrosion risks, ensuring reliable and efficient operation of heating and cooling systems.
Implementation Method 1
the main pipe (1) is fusion-welded to at least one functional unit (3, 4, 5, 6, 7)
Implementation Method 2
At least one sub-element of the functional units (3, 4, 5, 6, 7) arranged on top of the main pipe (1) is also fused to the main pipe (1), preferably by welding, in particular by means of laser welding
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 3a~3b
AI summary
The system has valves (3), flow indicators, thermostats, emptying elements (6), and ventilation elements (7) flushingly arranged relative to each other and in a right angle to a main axis (20) of a central main pipe (1). The main pipe includes enlargements with two joining surfaces in a region of the valves, the indicators, the thermostats, and the elements. Connections and an opening (12) of the valves, the indicators, the thermostats, and the elements are undetachably and sealingly connected with the pipe. The pipe is designed planar in a joining region of the opening and the connections. An independent claim is also included for a method for producing threads at parts of a pipe manifold system.