| JPH10113993 | FIXING JIG FOR CONNECTING PIPE |
| JP2002174390 | ELECTRICALLY FUSED SADDLE TYPE JOINT |
| WO1988000668A1 | 1988-01-28 |
| US20160123507A1 | 2016-05-05 | |||
| US4670207A | 1987-06-02 | |||
| JP2017160925A | 2017-09-14 | |||
| US3726548A | 1973-04-10 |
| Claim #1 Improved design of welded PE-RT joints and reinforcedjoints ofthe type PE of the size 16-125 mm used for piping in PE-RT/Aluminum/PE-RT five-layer pipes with thermal and arc welding at two diagonal areas and with five outer layers of the pipe designed with an inner area in the joints consisting of four grooves of the depth 0.5 mm to 2 mm hereinafter referred to as receptacle or female connector. The grooves have been made to prevent air from entering the layers of thermal or arc welds and the formation of cracks or holes in the welded area and to integrate and strengthen the thermal welds in the pipe and fittings. For thermal or arc welding, a part of the inner layer of the pipe designed as the male connector is welded into and connected to the inner section of the pipe once inside the pipe, forming a monolithic integrated section. It is important to note that in the proposed design, once welded to the fittings, the pipes will not undergo breakage as a result of bending. The design also completely addresses the porosity issue in this type of fittings. Claim #2 Arc welded fittings made of PE-RT plastic materials where a connection to a pipe is made by melting the outer layer of the five-layer PE-RT /Aluminum/PE-RT pipe into the female connection of the fittings and melting the inner layer of the pipe into the male connection of the fittings using the heat created by the current passing through a resistor properly placed into the body of the fittings. Claim #3 Improved design of welded connection and strengthened PE-RT fittings of the size 16-125 mm with mixed entries, consisting of fittings where one end is fitted into a plastic body using a brass nut threaded in the form of a pipe coupling with a core used for the sizes 1/2 and % and other sizes and designed for fitting metal pipes and any threaded faucet. The other end is designed for being attached to a five- layer PE-RT /Aluminum/PE-RT pipe through thermal or arc welding by co-melting the outer or exterior layer of the pipe into the female connector and the inner or interior layer into the exterior of the male connector (as shown in diagram 5- page 2). Claim #4 Improved design of aluminum molds to create heat for thermal welding of the joints and connections described in this patent claim in order to connect five-layer PE-RT /PE-RT /Aluminum pipes with the fittings covered in this claim which, once the heater is installed, enables thermal welding of pipes and fittings. The special technique used in designing these welding molds enables co-heating of female and male connectors of the fittings and the exterior and interior areas of the pipe for the purpose of thermal welding. The molds are divided into two sections, namely the heating section and joints, where the heating mold, in turn, is designed in two sections: The first section is the aluminum mold used to heat the pipe and consists of two separate subsections: (1) Improved aluminum mold used to heat the interior core or the inner layer of the five-layer PE-RT /PE-RT /Aluminum pipe (as shown in Diagram 2 - page 1, region 1). (2) Aluminum mold used to heat the exterior or outer layer of the five-layer PE- RT/PE-RT/Aluminum pipe (as shown in Diagram 3- page 1, region 3) The two subsections described above are designed in a way that enables stack (top on top) installation for co-heating of the exterior and interior of the pipes (as shown in Diagrams 2 and 3 - page 1, regions 2 and 5). The second section of the improved aluminum mold used to heat the joints: The heating mold can independently conduct heat to the two regions on the exterior of the male connection and the interior of the female connection (as shown in Diagram 4- page 1, regions 6 and 7). Claim # 5 Improved design of a simple coupling or a reducer with an L-shaped connector having a 90-degree or 45-degree angle using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with both ends fitted into a five- layer PE-RT/Aluminum/PE-RT pipe using arc or thermal welding where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector (as shown in Diagram 1- Page 1) Claim #6 Improved design of the L-shaped connector with a right angle using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with mixed entrance where one end is in the form of a brass coupling or a core used to join metal pipes and faucets through a threaded section embedded into the plastic part. The other end is used to apply arc or thermal welding to fit into a five- layer PE-RT /Aluminum/PE-RTpipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #7 Improved design of a simple coupling or a reducer using the plastic materials PERT of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm with two arc or thermally welded ends to fit into a five-layer PE-RT /Aluminum/PE-RT pipe at two connection points by co-melting the outer layer or exterior of the five-layer pipe into the female connector and the inner layer or interior of the five-layer pipe into the exterior of the male connector. Claim #8 Improved design of simple Y coupling and a reducer using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm with two arc and thermally welded ends for fitting into a five-layer PE-RT/Aluminum/PE-RT pipe at two connection points by co-melting the outer layer or exterior of the five-layer pipe into the female connector and the inner layer or interior of the five-layer pipe into the exterior of the male connector. Claim #9 Improved design of a right-angle L connection with a wall bracket using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, where one end is in the form of a brass coupling or a core used to join metal pipes and faucets through a threaded section embedded into the plastic part. A plastic section is used a bracket for wall mounting. The other end used to apply arc or thermal welding to fit into a five-layer PE-RT/PE-RT/Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #10 Improved design of simple Y coupling and a reducer using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with mixed entrance where one end is in the form of a brass coupling or a core used to join metal pipes and faucets through a threaded section embedded into the plastic part. The other end is used to apply arc or thermal welding to fit into a five-layer PE-RT/PE- RT/Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #11 Improved design of simple Y coupling and a reducer with wall brackets using PERT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with mixed entrance where one end is in the form of a brass coupling or a core used to join metal pipes and faucets through a threaded section embedded into the plastic part A plastic section is used a bracket for wall mounting. The other end is used to apply arc or thermal welding to fit into a five-layer PE-RT/PE- RT/Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #12 Improved design of a simple coupling and a reducer using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with mixed entrance where one end is in the form of a brass coupling or a core used to join metal pipes and faucets through a threaded section embedded into the plastic part. The other end is used to apply arc or thermal welding to fit into a five-layer PE-RT/PE- RT/Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #13 Improved design of a cap using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with one end arc or thermally welded into a five-layer PE-RT /PE-RT /Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #14 Improved design of a shut-off valve using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with two ends arc or thermally welded into a five-layer PE-RT/PE-RT/Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five- layer pipe into the female connector and the interior or the inner layer of the five- layer pipe into the exterior of the male connector. The fluid through the valve is shut off or back on using ABS plastic balls or brass balls embedded using a separate section to control the center of gravity of the valve before plastic is injected into the mold. Claim #15 Improved design of a stop valve using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with one-end mixed entrance where the end is in the form of a brass coupling to join the upper part of the valve through a threaded section embedded into the plastic part. The other end is used to apply arc or thermal welding to fit into a five-layer PE-RT/PE- RT/Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #16 Improved design of a brass flange for union nut using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with one end arc or thermally welded into a five-layer PE-RT/PE-RT/Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #17 Improved design of union nut using PE-RT plastic materials of the sizes 16, 20, 25, 32, 40, 50, 63, 75, 90, 110, and 125 mm, with one end arc or thermally welded into a five-layer PE-RT /PE-RT /Aluminum pipe where connection is formed in the joint region by co-melting the exterior or the outer layer of the five-layer pipe into the female connector and the interior or the inner layer of the five-layer pipe into the exterior of the male connector. Claim #18 Novel design of a collector using PE-RT materials with mixed entrance of brass nut and core materials that can be used to connect primary pipes to secondary pipes for the purpose of distributing the flow. The brass nut or core embedded into the PE-RT plastic body is used to fit the assembly into the faucet to control the flow input into the branched PE-RT/Aluminium/PE-RT pipes or any metal pipe. |
PE-RT plastic fittings capable of being arc or thermally welded for PERT /Aluminum/PE-RT five-layer pipes and related welding molds and joints.- Technical Application Area
Piping system in building installations and industrial applications for cold water and hot water at high temperatures - Technical Problem and Statement of the Object
(a) Broken welds in PE-RT/Aluminum/PE-RT pipes in the welding area with PE-RT joints that can be fixed at the interior or the exterior of the pipe where it is connected to the fittings: after welding the pipe to PE-RT fittings, bending in the pipe can result in a breakage in the welding spot. This will detach the pipe from the fittings. The situation can cause problems in terms of subsidence after earthquakes or following completion of construction. The objective of the invention is to address this problem.
(b) Molten male connector in PE-RT connections at the interior of the five- layer pipe and the exterior of the pipe layer where it fits into the fitting: given the current design of welded molds that weaken male connectors, this weak connection can cause problems during installation of pipes and fittings. It can also result in poor sealing or broken welds. The present invention addresses this problem by changing the size of weld mold assembly and increasing the length of the female connector.
(c) Weld porosity and poor sealing function in welding PE-RT /Aluminum/PE- RT five-layer pipes with PE-RT joints at the exterior and interior parts of the pipe where in fits into the fittings: The weld molds and sizes used in similar designs cause porosity in male and female connectors for any type of welds in pipes and fittings. The present invention also addresses this problem. - Description of the Existing Knowledge and History of Progresses in Connection to the Claimed Invention:
In the past, hot and cold water piping in buildings was implemented using galvanized pipes. With the introduction of plastic pipes fifteen years ago into the construction industry, a new practice found its way into the piping system. Polymer pipes with applications for hot and cold water made of different materials including polypropylene and the so called five-layer pipes (consisting of two polymer layer, one aluminum layer, and two adhesive layers for attaching the polymer layers to the aluminum layer) were introduced to the market, with all fittings connecting polypropylene, polymer, or five-layer pipes made of pressed brass materials and union nuts with push- fit applications. With the advent of PE-RT fittings, a new technology was designed for polymer or welded fittings used for PE-RT/Aluminum/PE-RT five-layer pipes. An important point to note is the special design technique incorporated into this type of fittings where two regions are connected by comelting the outer or exterior layer of the pipe into the female connector and the inner or interior layer into the exterior of the male connector. It is also important to note that the proposed invention and design address the technical problems encountered when implementing piping systems with PERT fittings that can be welded into interior section or exterior layer of PE- RT/Aluminum-PE-RT five-layer pipes which can be widely used by consumers and others in market. - Description of the Invention, the Technical Problem and the Proposed Solution:
5-1 Broken welds in PE-RT/Aluminum/PE-RT pipes at the section welded into the PE-RT fittings at two regions connected through interior and exterior section of the pipe: The following steps were taken to address this problem: The length of the female connector was increased to provide further support for the pipe. To further clarify this, a description of improved fittings of four sizes is provided as an example:
(a) For the size 16 mm, the female connectors available in the market are 8.92 mm long while this length reaches 15.82 mm in the improved fittings.
(b) For the size 20 mm, the female connectors available in the market are 9.60 mm long while this length reaches 16.18 mm in the improved fittings.
(c) For the size 25 mm, the female connectors available in the market are 9.50 mm long while this length reaches 18.32 mm in the improved fittings.
(d) For the size 32 mm, the female connectors available in the market are 9.8 mm long while this length reaches 20 mm in the improved fittings.
5-2 Molten male connector in PE-RT connections at the interior of the five- layer pipe and the exterior of the pipe layer where it fits into the fitting (This is one reason for detachment of the pipe from the fittings).
To resolve this issue, the length of the male connector was increased in order to strengthen the base of the male connector.
To further clarify this, a description of improved fittings of four sizes is provided as an example: (a) For the size 16 mm, the male connectors available in the market are 13.55 mm long while this length reaches 14.82 mm in the improved fittings.
(b) For the size 20 mm, the male connectors available in the market are 13.9 mm long while this length reaches 15.18 mm in the improved fittings.
(c) For the size 25 mm, the male connectors available in the market are 16 mm long while this length reaches 17.32 mm in the improved fittings.
(d) For the size 32 mm, the male connectors available in the market are 18 mm long while this length reaches 19 mm in the improved fittings.
5-3 Weld porosity and poor sealing function in welding PE- RT/Aluminum/PE-RT five-layer pipes with PE-RT joints at the exterior and interior parts of the pipe where in fits into the fittings: (this is one reason for detachment of pipe from the fitting).
5-3-1 The length of the welding mold used as an interior source of heat in the five-layer pipe was increased to complete the full weld segment length:
To further clarify this, a description of improved welding mold in four sizes is provided as an example:
(a) For the size 16 mm, the weld molds available in the market for PE-RT five- layer pipes are 15.1 mm long (in terms of effective thermal length) while this length reaches 16 mm in the improved molds.
(b) For the size 20 mm, the weld molds available in the market for PE-RT five- layer pipes are 16.2 mm long (in terms of effective thermal length) while this length reaches 18 mm in the improved molds.
(c) For the size 25 mm, the weld molds available in the market for PE-RT five- layer pipes are 17.95 mm long (in terms of effective thermal length) while this length reaches 21 mm in the improved molds.
(d) For the size 32 mm, the weld molds available in the market for PE-RT five- layer pipes are 20.4 mm long (in terms of effective thermal length) while this length reaches 22.5 mm in the improved molds.
5-3-2 Reduced length of thermal welding mold of the male connector to prevent heat transfer to the base of the male connector.
To further clarify this, a description of improved welding mold in four sizes is provided as an example:
(a) For the size 16 mm, the weld molds available in the market for male connectors are 16 mm long (in terms of effective thermal length) while this length is reduced to 15mm in the improved molds. (b) For the size 20 mm, the weld molds available in the market for male connectors are 16.1 mm long (in terms of effective thermal length) while this length is reduced tol5.68 mm in the improved molds.
(c) For the size 25 mm, the weld molds available in the market for male connectors are 18.1 mm long (in terms of effective thermal length) while this length is reduced to 17.52 mm in the improved molds.
(d) For the size 32 mm, the weld molds available in the market for male connectors are 20.15 mm long (in terms of effective thermal length) while this length is reduced to 18.50 mm in the improved molds.
5-3-3 Reduced diameter of the heating mold for the female connector to accelerate the heating process and prevent over-melting in the male connector and thereby eliminate weld porosity:
To further clarify this, a description of improved welding mold in four sizes is provided as an example:
(a) For the size 16 mm, the diameter of the heating molds available in the market for female connectors is 15.9 mm while this diameter is reduced to 15.1 mm in the improved mold.
(b) For the size 20 mm, the diameter of the heating molds available in the market for female connectors is 19.92 mm while this diameter is reduced to 19.31 mm in the improved mold.
(c) For the size 25 mm, the diameter of the heating molds available in the market for female connectors is 24.9 mm while this diameter is reduced to 24.7 mm in the improved mold.
(d) For the size 32 mm, the diameter of the heating molds available in the market for female connectors is 31.91 mm while this diameter is reduced to 31.82 mm in the improved mold.
6- Description of Invention Diagrams and Figures
Diagram #1-Page 1: improved PE-RT L-shaped fitting at the interior and the exterior sections of the five-layer pipe.
This diagram shows a section of the improved fittings with two thermally welded ends where one end is used to thermally weld the pipe into the fittings and the other end consists of the fitting parts as described below:
Region 1: inner layer of the five-layer pipe
Region 2: Aluminum layer in the five-layer pipe
Region 3: exterior or outer layer of the five-layer pipe Region 4: Arc or thermally welded female connector fitted into the pipe Region 5: Arc or thermally welded male connector fitted into the pipe at the exterior section of the male connector
Region 6: Brass pipe inside the male connector used to maintain the accurate size and calibration at the connection region
Region 7: A groove in the female connector embedded to let air out during welding
Region 8: Female connector with four grooves (this section was elongated to provide better support for the pipe and prevent broken welds).
Region 9: The exterior section of the male connector designed to be arc or thermally welded into the interior of the pipe (this section was elongated to strengthen the base of the male connector). This prevents melting in the base of the male connector during installation of pipes and fittings.
Diagram #2- Page 1: improved aluminum mold:
The diagram shows a section of the aluminum mold used to transfer heat to the interior section of the PE-RT /PE-RT /Aluminum five-layer pipe consisting of the parts described below:
Region 1: used to enable thermal welding of the interior of the pipe (this section was made longer to prevent weld porosity)
Region 2: used to assemble the mold on the heating section of the exterior of the pipe, i.e. Region 5- Diagram #3 (to transfer heat simultaneously to the interior and the exterior sections of the pipe).
Diagram #3- Page 1: thermally conductive aluminum mold
The diagram shows a section of the aluminum mold used to heat the exterior or outer layer of the PE-RT/Aluminum/PE-RT five-layer pipe consisting of the parts described below:
Region 3: used to enable thermal welding of the exterior of the five-layer pipe Region 4: holes embedded to let air out when the pipe enters Region 3 in order to create the heat needed for thermal welding
Region 5: this region is added for mounting the heating mold for the interior layer of the pipe.
Diagram #4-page 1: improved heating mold for the fittings
This diagram shows the layout of a section used in the form of a mold to transfer heat to the fittings. It simultaneously heats the exterior of the male and female connectors in order to enable thermal welding. This heating mold consists of the parts described below: Region 7: the heating section for the male connector (the welding mold for the male connector was reduced in length to prevent heat from reaching the base of the male connector).
Region 8: the heating section for the female connector (the heating mold for the female connector was reduced in diameter to accelerate transfer of heat to the fitting and prevent over-melting in the male connector).
Diagram # 5- page 2: improved fitting with mixed PE-RT entrance at the interior section and the exterior layer of the five-layer pipe.
The diagram shows a section of the fittings with mixed entrance where one end is used for connection to a metal pipe or faucet and the other end is used to apply arc or thermal welding on the PE-RT/Aluminium/PE-RT five-layer pipe with the parts described below:
Region 6: a brass pipe used to maintain the size and calibration accuracy in the male connector.
Region 7: a groove in the female connector embedded to let air out during welding. The size of the groove is 0.5 mm min and 1.5 mm max, depending on the depth of the groove.
Region 8: a female connector embedded to enable thermal welding onto the exterior layer of the pipe (The length of this region was increased relative to the fittings available in the market in order to provide further support for the pipe and increased resistance to broken welds and to prevent molten base on the male connector during installation).
Region 9: the exterior of the male connector used to thermally weld onto the interior of the pipe (This section is relatively longer than those typically found in the market and prevents molten base of the male connector during welding).
Region 10: A metal coupling or core preferably made of a brass alloy for connecting the pipe and faucet to the piping network.
Diagram #6-page 2: L-shaped PE-RT fitting available in the market formed by connecting the interior of exterior sections of the five-layer pipe:
This diagram shows a section of the improved fittings with thermally molten and welded double-ends where one end is used to thermally weld the pipe into the fittings and the other end consists of the parts described below: Region 1: inner layer of the five-layer pipe Region 2: Aluminum layer in the five-layer pipe
Region 3: exterior or outer layer of the five-layer pipe
Region 4: Arc or thermally welded female connector fitted into the pipe Region 5: Arc or thermally welded male connector fitted into the pipe at the exterior section of the male connector
Region 6: Brass pipe inside the male connector used to maintain the accurate size and calibration at the connection region
Region 7: A groove in the female connector embedded to let air out during welding
Region 8: Female connector with four grooves (this section was elongated to provide better support for the pipe and prevent broken welds).
Region 9: The exterior section of the male connector designed to be arc or thermally welded into the interior of the pipe (this section was shortened to strengthen the base of the male connector. This prevents melting in the base of the male connector during installation of pipes and fittings).
Diagram #7-page 2: a fitting available in the market with a mixed PE-RT entrance to enable connection at the exterior and interior sections of the five-layer pipe:
The diagram shows a section of the fittings with mixed entrance where one end is used for connection to a metal pipe or faucet and the other end is used to apply arc or thermal welding on the PE-RT/Aluminium/PE-RT five-layer pipe with the parts described below:
Region 6: a brass pipe used to maintain the size and calibration accuracy in the male connector.
Region 7: a groove in the female connector embedded to let air out during welding. The size of the groove is 0.5 mm min and 1.5 mm max, depending on the depth of the groove.
Region 8: a female connector embedded to enable thermal welding onto the exterior layer of the pipe (The typical length of this section is shorter in the existing products relative to the claimed invention and this is one of the reasons behind the broken welds).
Region 9: the exterior of the male connector used to thermally weld onto the interior of the pipe (This section in the invention is relatively longer than those typically found in the market and prevents molten base of the male connector during welding).
Region 10: A metal coupling or core preferably made of a brass alloy for connecting the pipe and faucet to the piping network. - Advantages of the claimed invention over the previous inventions, which explains technical implications and originality of the present invention:
(a) The invention was designed in a way that completely addresses the issues found in previous inventions in terms of broken welds at the PE-RT joint on the interior and exterior section of the pipe or at the points where PE- RT/PE-RT/Aluminum pipe is jointed into fitting, bending in the pipe can result in a breakage in the welding spot, and leakage and subsidence caused as a result of pressure after earthquakes or following completion of construction.
(b) The design is intended to fix the problem of weld porosity in pipes and fittings, thereby essentially preventing breakage in the welded region or water leakage in the long term. - Description of an implementation technique for practical application of the invention:
First, the designed welding molds are installed onto the welding machines used for the plastic pipes to ensure that the welding machine is heated up to 210 °C. Next, the pipe and the relevant fitting is placed into the welding mold and is manually pushed slowly until the pipe touches the end point of the mold and the fitting reaches this end point in the welding mold. Then, the pipe and the fitting are simultaneously removed from the mold. The pipe is then placed into the fitting for plastic welding. Finally, through this process, the pipe and the fitting are inseparably joined to form a joint free of any potential leakage. - Applications of the invented connection
The invention finds applications in implementing PE-RT/Aluminum/PE-RT five-layer piping networks for hot and cold water at buildings and industrial facilities, boiler rooms, radiators, and piping for high-temperature hot water.