Pneumatic Test Plug With Integrated Pressure Relief Valve
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Solution Overview
Problem
Existing pneumatic test plugs for pipe systems lack effective pressure regulation, leading to potential overinflation issues, damage, and disruption of testing due to unreliable pressure relief mechanisms and the need for external equipment, which complicates operator use and increases testing time.
Innovation Solution
A pneumatic test plug with an inflatable bladder and an integrated inflation valve that includes a release channel to automatically vent excess air when overinflated, preventing damage and ensuring reliable sealing without external equipment, featuring a sealing portion that elastically returns to its closed position after pressure relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external pressure regulators or relief devices are used, then overinflation protection is provided, but device complexity and operator burden increase
Solution Approach 1:
The pressure relief function is merged with the inflation valve by integrating a relief channel directly into the valve structure. This allows the bladder to automatically vent excess pressure through the relief channel when the sealing portion is pushed away from the valve body, eliminating the need for separate external pressure relief devices while maintaining overinflation protection.
2Reliability
If relief valves are positioned on the backside of the bladder, then pressure relief is provided, but excess air is released into the pipe system disrupting testing
Solution Approach 1:
The inflation valve body acts as an intermediary structure that provides a dedicated relief channel venting directly to the exterior environment. This positioned relief pathway prevents excess air from being released into the pipe system behind the bladder, eliminating testing disruption while maintaining pressure relief functionality.
3Ease of operation
If operator diligence and external gauges are relied upon, then inflation control is achieved, but operator burden and time requirements increase
Solution Approach 1:
The system performs self-regulation of inflation pressure through the integrated relief channel. When the bladder becomes overinflated, the sealing portion automatically pushes away from the valve body and vents excess pressure without requiring operator intervention, external gauges, or additional settings, thereby reducing operator burden and testing time.
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 solution provides a user-friendly, reliable, and repeatable pneumatic test plug that prevents overinflation damage and maintains testing integrity by automatically releasing excess air, ensuring consistent results without requiring additional operator settings or external equipment.
Implementation Method 1
When the sealing portion is elastically deflected by overinflation of the bladder, the sealing portion uncovers the inlet of the release channel
Implementation Method 2
The sealing portion elastically returns to the sealed position when sufficient release of air has occurred
Data Source
AI summary
The present invention provides a pneumatic test plug that seals a portion of a pipe section having a generally cylindrical internal pipe wall. In general, the pneumatic test plug includes an inflation valve mounted in the bladder wall of an inflatable bladder. The inflation valve includes a main air passageway through which air is introduced into the bladder and a separate release channel. The separate release channel includes an inlet disposed toward an interior end of the inflation valve and an outlet in fluid communication with an exterior environment outside the bladder. When in a sealed position, a sealing portion of the bladder engages the interior end of the inflation valve and sealingly closes the inlet of the release channel. When the sealing portion is elastically deflected by overinflation of the bladder, the sealing portion uncovers the inlet of the release channel to allow air to escape from the interior area of the bladder through the release channel to the exterior environment.