Stop Collar Manufacturing via Extrusion and Elastic Segmentation
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Solution Overview
Problem
Conventional stop collars for pipe fitting devices are difficult to machine precisely, cannot ensure accurate nut tightening, and are not reusable, leading to potential leakage and damage to pipes and fittings.
Innovation Solution
A method for manufacturing a stop collar with a 'C' shape using extrusion molding, heat treatment, and elastic members, coated with ceramic for easy identification and maintenance, allowing for precise fitting and repeatable use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to manufacture the stop collar, then production efficiency is improved, but manufacturing precision deteriorates
Solution Approach 1:
The stop collar is divided into two main parts: a rigid body portion (made via injection molding for high productivity) and an elastic member portion (made via separate molding for precision). This segmentation allows each part to be manufactured using the most suitable process for its functional requirements, resolving the contradiction between production efficiency and manufacturing precision.
Solution Approach 2:
The stop collar combines two different materials: a rigid material (such as nylon or polyacetal) for the body portion and an elastic material (such as rubber or elastomer) for the elastic member. This composite structure enables the rigid part to provide dimensional stability for precision while the elastic part provides the necessary compliance, thus achieving both high productivity through injection molding and high manufacturing precision.
2Strength
If the stop collar is made rigid, then structural strength is improved, but adaptability deteriorates
Solution Approach 1:
The stop collar is segmented into a rigid body portion that provides structural strength and an elastic member portion that provides adaptability. The rigid body maintains its shape and strength during installation, while the elastic member deforms to accommodate variations in pipe dimensions and fitting conditions, enabling repeatable uses across different applications.
Solution Approach 2:
The elastic member acts as a flexible element within the stop collar structure. This flexible component can deform elastically to adapt to different pipe sizes and installation conditions, while the overall structure maintains sufficient rigidity through the rigid body portion. This combination enables the stop collar to be reused multiple times with different pipes while maintaining structural integrity.
3Ease of manufacture
If the stop collar lacks elastic force, then manufacturing simplicity is improved, but reliability deteriorates
Solution Approach 1:
The stop collar is divided into a rigid body portion (manufactured via injection molding for simplicity) and an elastic member portion (integrated or separately molded for reliability). This segmentation allows the majority of the structure to be manufactured simply through injection molding, while only the critical sealing portion requires the additional complexity of elastic material processing, thus achieving a balance between manufacturing simplicity and sealing reliability.
Solution Approach 2:
The stop collar uses a composite structure combining rigid and elastic materials. The rigid material provides the main structural form that is easy to manufacture via injection molding, while the elastic material provides the necessary sealing force and reliability. This composite approach maintains manufacturing simplicity by using standard injection molding processes for both materials while achieving high reliability through the elastic sealing action.
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 stop collar ensures easy assembly, prevents pipe damage, and allows for optimal connection verification, maintaining a perfect sealing state while being reusable and resistant to slipping during nut tightening.
Implementation Method 1
an elastic member (220) coupled to the front surface of the body (122)
Implementation Method 2
The extrudate is then increased in hardness through heat treatment
Implementation Method 3
ceramic having any one of red, blue, yellow, and black is coated onto the surface of the heat-treated extrudate
Data Source
AI summary
A method for manufacturing a stop collar for a pipe fitting device. A raw material is prepared and heated to a temperature of more than 350° C. The heated raw material is extruded to obtain an extrudate taking a C shape at the front surface thereof and having one or more check protrusions formed on the outer surface thereof. The extrudate is subjected to a solution treatment, cooling treatment, and cutting. An elastic member is prepared from a metal spring steel and folded portions are formed thereon by multi-foaming. The extrudate and the elastic member are coupled to form the stop collar and burrs are removed from the stop collar. The surface of the stop collar are coated with ceramic to provide identification of the pipe use.