Thermal Welding Applicator for Adhesive-Free Gap Sealing
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Solution Overview
Problem
Existing methods for closing gaps in materials covering pipes, such as adhesives, sealing tapes, and clamps, suffer from disadvantages including high cost, environmental impact, poor insulation, and mechanical instability, which have not been adequately addressed.
Innovation Solution
A device and method for thermally welding thermally weldable materials using a heating device to heat a gas, which is directed through an applicator to melt and bond adjacent sections of the material within the gap, eliminating the need for adhesives and tapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to close gaps in material, then the gap can be sealed, but the adhesive may fail due to temperature dependence, soil the installer, and have strong odor
Solution Approach 1:
The patent replaces the chemical bonding mechanism of adhesives with a thermal welding mechanism. A heating device melts the thermally weldable material at the gap interface, and the melted material bonds the adjacent sections together upon cooling. This eliminates adhesive application, avoiding soilage and odor issues while providing reliable bonding.
Solution Approach 2:
The patent changes the bonding mechanism from chemical (adhesive) to thermal (melting and solidifying). By controlling the temperature parameter through the heating device, the material transitions from solid to melted state at the gap interface, then solidifies to form a strong bond, eliminating the need for adhesives.
2Reliability
If sealing tapes are used to close gaps, then the gap can be sealed, but the tapes are relatively expensive and may have lower thermal insulation properties
Solution Approach 1:
The patent uses the material itself to close the gap. The thermally weldable material is heated at the gap interface, and the melted material automatically bonds the adjacent sections together. This self-bonding mechanism eliminates the need for separate sealing tapes, reducing cost while maintaining or improving thermal insulation properties.
Solution Approach 2:
The patent merges the gap-closing function with the insulation material itself. Instead of using separate sealing tapes, the insulation material is heated and bonds to itself at the gap interface, combining the sealing function with the insulation function in a single integrated solution.
3Ease of operation
If clamps are used to close gaps, then the gap can be mechanically closed, but the gap remains mechanically open leading to poor insulation and media transmission
Solution Approach 1:
The patent replaces the mechanical clamping system with a thermal welding system. Instead of using clamps to mechanically close the gap, the heating device melts the material at the gap interface, creating a bonded connection that provides both mechanical closure and reliable insulation, eliminating the limitations of mechanical clamps.
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
Provides a strong, even bond with high sealing effectiveness and improved insulation, while avoiding the drawbacks of traditional closure methods.
Implementation Method 1
at least one heating device configured to heat at least one gas
Implementation Method 2
discharge the heated gas at least partially into the gap to at least partially melt at least one of the adjacent sections of the material
Data Source
Figure 1~2
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AI summary
The present invention relates to a device (10) for thermally welding at least one thermally weldable material (12). The device (10) includes at least one heating device (26) configured to heat at least one gas and at least one applicator (22) configured to be inserted at least partially in at least one gap (14) between at least two adjacent sections (16, 18) of the material (12), during operation of the device (10). The applicator (22) includes at least one channel (40) for guiding the heated gas at least partially therethrough. The channel (40) is configured to discharge the heated gas at least partially into the gap (14) to at least partially melt at least one of the adjacent sections (16, 18) of the material (12), in a state in which the applicator (22) is inserted at least partially between the adjacent sections (16, 18) of the material (12). The present invention further relates to a kit and a method.