Resilient Sealing Purge Plug for Welding Nozzles
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Solution Overview
Problem
Existing purge plug systems for welding applications are limited by their need for threading mechanisms and lack of interchangeability across different tubing or pipe sizes, increasing material and labor costs and inefficiency.
Innovation Solution
A purge plug with a central body and annularly disposed resilient sealing members that can expand or decompress to seal various inner diameters and cross-sectional configurations, eliminating the need for threading and allowing use across a range of diameters from 2.54 cm to 15.24 cm, with flexible sealing members that form an interference fit with the tubing or pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threading mechanism is used to attach purge plug, then secure connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the threading mechanism entirely from the purge plug design. Instead of using threads to attach the purge plug to the welding nozzle, the invention uses a simple push-fit insertion method where the purge plug is inserted directly into the nozzle opening and held in place by friction and the sealing element, eliminating complex threading components
Solution Approach 2:
Instead of using external threading to create a secure connection, the invention inverts the approach by using internal friction and sealing pressure within the nozzle-bore to hold the purge plug in place. The sealing element expands or flexes to create frictional engagement with the nozzle interior surfaces, reversing the traditional external thread engagement method
2Reliability
If different sizes of purge plugs are used for different tubing sizes, then proper sealing is achieved, but interchangeability and productivity decrease
Solution Approach 1:
The patent designs a universal purge plug that can be used with welding nozzles of various sizes. The sealing element is made of resilient material that can expand or flex to accommodate different nozzle bore diameters, allowing a single purge plug design to function across multiple nozzle sizes rather than requiring size-specific plugs
Solution Approach 2:
The sealing element incorporates dynamic properties by using resilient or flexible material that can change its dimensions. The element expands radially when inserted into larger nozzles and contracts for smaller nozzles, dynamically adapting to different bore sizes while maintaining effective sealing, rather than being a fixed rigid structure
3Reliability
If tape is used to seal the opening, then gas purging is achieved, but material cost and labor time increase
Solution Approach 1:
The purge plug is designed as a self-contained sealing device where the sealing function is integrated into the plug body itself through the resilient sealing element. The plug creates its own seal upon insertion without requiring external materials like tape or additional sealing components, making the system self-sufficient and eliminating separate sealing steps
Solution Approach 2:
The invention merges the sealing function with the purge plug body by integrating the sealing element directly onto or as part of the plug structure. This combination eliminates the need for separate tape application or additional sealing operations, consolidating multiple functions (purging and sealing) into a single component
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
Enables efficient and cost-effective gas purging across different tubing sizes without mechanical means, ensuring a reliable seal and easy placement/removal, improving the interchangeability and efficiency of the purging process.
Implementation Method 1
the sealing member is sufficiently resilient and capable of expanding or decompressing mechanically to cover and substantially seal a space between the central body of the purge plug and the inner walls of a tubing or pipe
Implementation Method 2
inserting the purge plug into the tubing by pushing the annular flexible sealing member against the inner walls of the tubing so that edge portions of the annular sealing member bends and wherein the bent edge portions of the flexible sealing member mechanically decompress and push against the inner walls
Data Source
AI summary
A purge plug for welding applications is provided that can be interchangeably used to seal tubing, pipes, or the like of various diameter or cross-sectional area. The purge plug has a central body with a male connector and a diffuser disposed on the end portions. The purge plug also includes one or more flexible seals annularly disposed around the central body. In some implementations, the diameter of the flexible seals is slightly larger than the diameter of the tubing or pipe. When the purge plug is inserted into the tubing or pipe, the resiliency of the seal allow the seal to expand mechanically and flex against the inner walls of the tubing, thus sealingly engage with the inner walls.