Description:[0032] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0033] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0034] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
[0035] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0036] In some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0037] The disclosure provides a hollow cylindrical insert (100) designed for socket fusion welding of thermoplastic pipes. The insert (100) may be constructed from materials resistant to high temperatures, fusion with pipe at welding temperature, and having low thermal conductivity, such as at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide and/or alike.
[0038] The cylindrical body (102) of the insert (100) can be placed within a socket die (106) to ensure uniform depth control, preventing excessive melting and deformation of the pipe face. The insert (100) may stop the pipe (112) before it reaches the end of the socket die (106), maintaining a smooth internal diameter for unobstructed water flow and optimal system performance. The insert (100) can be positioned at the center of the socket die (106), ensuring effective function and preventing inward bending. A sufficient gap may be maintained between the insert (100) and the curved inner surface of the socket die (106) to prevent heat transfer, preserving the integrity of the insert (100). The outer diameter (108) of the insert (100) can be equal to or greater than the inner diameter of the pipe (112), ensuring proper fit and function. This solution may enhance installation efficiency, reduce preparation time, and improve the overall quality of welds, making it a valuable improvement for thermoplastic pipe welding applications.
[0039] According to an embodiment, the hollow cylindrical insert (100) may be positioned at the center of the socket die (106) to ensure uniform depth control during the socket fusion welding process. This positioning may allow the insert (100) to stop the pipe (112) before it reaches the end of the socket die (106), potentially preventing excessive melting and deformation of the pipe face. The outer diameter (108) of the hollow cylindrical insert (100) may be equal to or greater than the inner diameter of the pipe, which can ensure a proper fit and function within the socket die (106). This configuration may also contribute to maintaining a smooth internal diameter of the pipe, which can ensure unobstructed water flow, optimal system performance, and long-term reliability. The hollow cylindrical insert (100) may be constructed from materials resistant to high temperatures, fusion with pipe at welding temperature, and having low thermal conductivity, such as at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide and/or alike.
[0040] These materials may allow the insert (100) to withstand the high temperatures, exceeding even 320 degree Celsius, involved in the welding process while preventing fusion with the pipe material. Additionally, a sufficient gap may be maintained between the hollow cylindrical insert (100) and the curved inner surface of the socket die (106) to prevent heat transfer, which can maintain the integrity of the insert (100) and prevent deformation. This setup may eliminate the need for manual depth control tools, such as cold rings or depth gauges, thereby automating aspects of the welding process and reducing errors. The integration of the hollow cylindrical insert (100) with existing socket fusion equipment may enhance installation efficiency, reduce preparation time, and improve the overall quality of welds, making it a versatile and valuable improvement for thermoplastic pipe welding applications.
[0041] According to another embodiment, the hollow cylindrical insert (100) may be utilized to maintain a smooth internal diameter of the pipe (112), which can ensure unobstructed water flow, optimal system performance, and long-term reliability. This may be achieved by the insert's ability to stop the pipe before it reaches the end of the socket die (106), thereby preventing excessive melting and deformation of the pipe face. The insert (100) may be constructed from materials resistant to high temperatures, fusion with pipe at welding temperature, and having low thermal conductivity, such as at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide, and/or alike, which can withstand the high temperatures involved in the socket fusion welding process. The insert's design may eliminate the need for manual depth control tools, automating aspects of the welding process and reducing errors. The insert (100) may be positioned at the center of the socket die (106), ensuring proper fit and function. Additionally, a sufficient gap may be maintained between the hollow cylindrical insert (100) and the curved inner surface of the socket die (106) to prevent heat transfer, which can maintain the integrity of the insert (100) and prevent deformation.
[0042] The integration of the insert (100) with existing socket fusion equipment may enhance installation efficiency, reduce preparation time, and improve the overall quality of welds. This solution may be compatible with various thermoplastic materials including but not limited to Polypropylene Random Copolymer (PP-R), Polypropylene Block Copolymer (PP-B), Polypropylene Homopolymer (PP-H), Polyethylene (PE), Polyethylene of Raised Temperature resistance (PE-RT), and PB (Polybutylene), making it a versatile and valuable improvement for thermoplastic pipe welding applications.
[0043] Referring now to FIG. 1, the technical drawing illustrates an exemplary view of the hollow cylindrical insert (100) designed for use in socket fusion welding of thermoplastic pipes. This insert (100) is a component in ensuring the integrity and quality of the welding process. The cylindrical body (102) is constructed from materials that are resistant to high temperatures and fusion with pipe at welding temperature, such as at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide and/or alike. These materials are chosen for their low thermal conductivity, which is essential in preventing heat transfer from the socket die (106) to the insert (100) itself, thereby maintaining the structural integrity of the pipe (112) during the welding process.
[0044] According to another embodiment, the hollow interior (104) of the insert (100) is placed within the socket die (106) and prevents excessive melting, deformation, and inward bending of the pipe face, which can compromise the weld quality. The outer diameter (108) of the insert (100) is equal to or greater than the inner diameter of the pipe (112), ensuring that the pipe is stopped at the correct depth within the socket die (106). This precise control of insertion depth eliminates the need for external tools or manual measurements, such as cold rings or depth gauges, thereby automating the process and reducing potential errors.
[0045] According to another embodiment, the insert's role in maintaining a smooth internal diameter of the pipe is vital for ensuring unobstructed water flow, optimal system performance, and long-term reliability. By integrating seamlessly with existing socket fusion equipment, the hollow cylindrical insert (100) enhances installation efficiency and reduces preparation time. The positioning of the insert (100) at the center of the socket die (106) ensures uniform depth control and prevents inward bending of the pipe (112) during the welding process. This innovative solution addresses the challenges associated with traditional socket fusion welding methods, offering a versatile and valuable improvement for thermoplastic pipe welding applications.
[0046] FIG. 2(A) and FIG. 2(B) provide an isometric and cross-sectional view of a hollow cylindrical insert (100) used in socket fusion welding (200). The isometric view illustrates the insert (100) positioned within the socket die (106), highlighting its role in ensuring uniform depth control and preventing excessive melting and deformation of the pipe (112). The insert (100) is designed to stop the pipe (112) before it reaches the end of the socket die (106), thereby maintaining a smooth internal diameter of the pipe, which is important for ensuring unobstructed water flow and optimal system performance.
[0047] According to another embodiment, the cross-sectional view further emphasizes the insert's placement and function. Constructed from materials resistant to high temperatures and fusion with pipe at welding temperature, such as at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide and/or alike, the insert (100) is strategically positioned to prevent the pipe (112) from advancing too far into the socket die (106). This design feature is important for avoiding inward bending and excessive melting of the pipe face, which can compromise the integrity of the weld and the pipe's functionality.
[0048] According to another embodiment, the hollow cylindrical insert (100) is central to the purpose of automating depth control in socket fusion welding, eliminating the need for manual tools like cold rings or depth gauges. By integrating seamlessly with existing socket fusion equipment, the insert (100) enhances installation efficiency, reduces preparation time, and improves the overall quality of welds. The cross-sectional view in FIG. 2(B) clearly shows how the insert (100) maintains a sufficient gap between itself and the curved inner surface of the socket die (106), preventing unwanted heat transfer and ensuring the insert's effectiveness in maintaining the pipe's internal diameter. This innovative solution is a valuable improvement for thermoplastic pipe welding applications, ensuring long-term reliability and system performance.
[0049] Referring now to FIG. 3(A), the exploded view illustrates the components involved in the socket fusion welding setup, which is integral to the hollow cylindrical insert (100). The setup includes a spigot die (114), a socket die (106), a heating plate (118), and the innovative hollow cylindrical insert (100), all of which work together to enhance the welding process. The socket die (106) and spigot die (114) are important for heating the pipe (112) and fitting (116), respectively. The heating plate (118) provides the necessary temperature for the fusion process, ensuring that the materials reach the required heat levels for effective welding.
[0050] According to a preferred embodiment, the hollow cylindrical insert (100) is a key component designed to ensure uniform depth control by stopping the pipe (112) before it reaches the end of the socket die (106). This prevents excessive melting and deformation of the pipe face, a common issue in traditional socket fusion welding methods. The insert (100) is constructed from materials resistant to high temperatures and fusion with pipe at welding temperature, such as at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide and/or alike. This construction allows the insert (100) to maintain a smooth internal diameter of the pipe, ensuring unobstructed water flow, optimal system performance, and long-term reliability.
[0051] According to a preferred embodiment, in the exploded view, the insert (100) is positioned at the center of the socket die (106), maintaining a sufficient gap between itself and the curved inner surface of the socket die (106) to prevent heat transfer. This strategic positioning and material choice help automate aspects of the welding process, reducing errors and eliminating the need for manual depth control tools like cold rings or depth gauges. The integration of the insert (100) with existing socket fusion equipment enhances installation efficiency, reduces preparation time, and improves the overall quality of welds, making it a versatile and valuable improvement for thermoplastic pipe welding applications.
[0052] According to another embodiment, the drawing also highlights the structural relationship between the socket die (106) and the hollow cylindrical insert (100). According to an embodiment, the insert (100) is positioned centrally within the socket die (106), maintaining a sufficient gap between itself and the curved inner surface of the socket die (106). This gap is essential to prevent heat transfer from the socket die (106) to the insert (100), further ensuring the stability and reliability of the welding process. The outer diameter (108) of the insert (100) is equal to or greater than the inner diameter of the pipe, which is a feature that allows it to stop the pipe effectively. This design not only enhances installation efficiency but also improves the overall quality of the welds by ensuring uniform depth control and preventing inward bending of the pipe.
[0053] Referring to FIG. 3(B), a pictorial view of pipe (112) interted into the fitting (116) is shown. According to yet another embodiment, finally, in the welded joint stage, the pipe (112) is inserted into the fitting (116) without twisting, and the assembly is allowed to cool naturally. This cooling process solidifies the bond, forming a strong, leak-proof joint. The hollow cylindrical insert (100) ensures that the pipe (112) does not reach the end of the socket die (106), maintaining the integrity of the weld and preventing inward bending or deformation. The insert's construction from high-temperature resistant materials such as at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide and/or alike further enhances the reliability and efficiency of the welding process.
[0054] Referring to FIG. 4, a flow chart of a method for socket fusion welding of thermoplastic pipes (200) is illustrated that comprises attaching (204) the socket die and the spigot die to a heating plate; heating (206) a socket die and a spigot die to a required temperature; inserting (208) the pipe into the socket die and the fitting on the spigot die which heats up pipe and fitting surfaces, wherein the socket die heats an outer diameter of a pipe and the spigot die heats an inner diameter of a fitting; inserting (212) the pipe into the fitting without twisting; and holding (214) the pipe in place to cool naturally, forming a strong, leak-proof bond. This further, at applicable stages depicted by a sequence of reference numerals, includes steps of steps of placing (202) a hollow cylindrical insert within the socket die, the hollow cylindrical insert constructed from materials resistant to high temperatures, fusion with pipe at welding temperature, and having low thermal conductivity; stopping (210) the pipe before it reaches an end of the socket die using the hollow cylindrical insert to prevent excessive melting and deformation of a face of the pipe; and maintaining (216) a smooth internal diameter of the pipe using the hollow cylindrical insert to ensure unobstructed water flow, optimal system performance, and long-term reliability. A person having average skill in the art would note that the required temperature for heating heating (202) a socket die and a spigot die is specified in DVS 2208-1.
[0055] According to an exemplary embodiment, the testing of pipes welded with the insert show no inward bending or bore obstructions. Specifically, the results from various materials demonstrate the effectiveness of the insert: for example, a PP-R pipe with approximately 25 mm diameter exhibits no inward bending and maintains a smooth internal bore; a PE-RT pipe with approximately 40 mm diameter allows for efficient water flow with no obstructions; and a PB pipe with approximately 20 mm diameter resulted in consistent and reliable weld quality. Experimental analysis reveals that water flow efficiency is improved by approximately 20% compared to conventional methods, and installation times are reduced due to the precise and consistent insertion depth. These findings suggest that the insert contributes to strong, reliable joints with minimal errors.
[0056] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “includes” and “including” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C … and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the scope of the appended claims.
[0057] While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the scope of the disclosure, as described in the claims.
, Claims:1. A hollow cylindrical insert (100) for use in socket fusion welding of thermoplastic pipes, the hollow cylindrical insert comprising:
a cylindrical body (102) constructed from materials resistant to high temperatures, fusion with pipe at welding temperature, and having low thermal conductivity;
a hollow interior (104) configured to allow placement of the hollow cylindrical insert (100) within a socket die (106); and
an outer diameter (108) equal to or greater than an inner diameter of a pipe (112) to be welded,
wherein the hollow cylindrical insert (100) is configured to:
stop the pipe (112) before it reaches an end of the socket die (106) to prevent excessive melting, inward bending and/or deformation of a face of the pipe (112); and
maintain a smooth internal diameter of the pipe (112) to ensure unobstructed water flow, optimal system performance, and long-term reliability.
2. The hollow cylindrical insert (100) according to claim 1, wherein the hollow cylindrical insert (100) is positioned at a center of the socket die (106).
3. The hollow cylindrical insert (100) according to claim 1, wherein a sufficient gap is maintained between the hollow cylindrical insert (100) and a curved inner surface of the socket die (106) to prevent heat transfer from the socket die (106) to the hollow cylindrical insert (100).
4. The hollow cylindrical insert (100) according to claim 1, wherein the hollow cylindrical insert (100) is constructed from at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide and/or alike.
5. A method for socket fusion welding of thermoplastic pipes (200), the method comprising:
attaching (204) the socket die and the spigot die to a heating plate;
heating (206) a socket die and a spigot die to a required temperature;
inserting (208) the pipe into the socket die and the fitting on the spigot die, that heats up pipe and fitting surfaces, wherein the socket die heats an outer diameter of a pipe and the spigot die heats an inner diameter of a fitting;
inserting (212) the pipe into the fitting without twisting; and
holding (214) the pipe in place to cool naturally, forming a strong, leak-proof bond,
wherein:
placing (202) a hollow cylindrical insert within the socket die, the hollow cylindrical insert constructed from materials resistant to high temperatures, fusion with pipe at welding temperature, and having low thermal conductivity;
stopping (210) the pipe before it reaches an end of the socket die using the hollow cylindrical insert to prevent excessive melting, inward bending and/or deformation of a face of the pipe; and
maintaining (216) a smooth internal diameter of the pipe using the hollow cylindrical insert to ensure unobstructed water flow, optimal system performance, and long-term reliability.
6. The method (200) according to claim 5, wherein the hollow cylindrical insert is positioned at a center of the socket die.
7. The method according to claim 5, wherein an outer diameter of the hollow cylindrical insert is equal to or greater than an inner diameter of the pipe.
8. The method (200) according to claim 5, wherein a sufficient gap is maintained between the hollow cylindrical insert and a curved inner surface of the socket die to prevent heat transfer from the socket die to the hollow cylindrical insert.
9. The method (200) according to claim 5, wherein the required temperature is specified in DVS 2208-1.
10. The method (200) according to claim 5, wherein the hollow cylindrical insert is constructed from at least one of polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyimide, polyamide-imide, polybenzimidazole, polysulfone, polyetherimide, and/or alike.