Fusion process for conduit

• US 20040251575A1
• Filed: 02/26/2004
• Published: 12/16/2004
• Est. Priority Date: 06/13/2003
• Status: Active Grant

• Current Assignee: Underground Solutions, Inc. (Aegion Corp.)
• Original Assignee: Underground Solutions Technologies Group Inc. (Aegion Corp.)
• Inventors: St. Onge, Henri, St. Onge, Bryan
• Granted Patent: US 6,982,051 B2
• Time in Patent Office: Days
• US Class Current: 264/162
• CPC Class Codes: B29C 2793/0081 before shaping
• CPC Class Codes: B29C 37/04 of welded articles, e.g. deburring or deflashing in combination with welding shaping the burr B29C66/32
• CPC Class Codes: B29C 53/20 of tubes
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/2015 being a single welding mirror comprising several separate heating surfaces in different planes, e.g. said heating surfaces having different temperatures
• CPC Class Codes: B29C 65/2061 by sliding
• CPC Class Codes: B29C 65/2092 and involving the use of a facer
• CPC Class Codes: B29C 65/7841 Holding or clamping means for handling purposes clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04
• CPC Class Codes: B29C 66/022 Mechanical pre-treatments, e.g. reshaping
• CPC Class Codes: B29C 66/02241 Cutting, e.g. by using waterjets, or sawing using heat B29C66/0246; cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article B29C69/005
• CPC Class Codes: B29C 66/02245 Abrading, e.g. grinding, sanding, sandblasting or scraping
• CPC Class Codes: B29C 66/032 Mechanical after-treatments deburring welded articles B29C37/04
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/5221 for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/80 General aspects of machine operations or constructions and parts thereof
• CPC Class Codes: B29C 66/91216 enabling contactless temperature measurements, e.g. using a pyrometer
• CPC Class Codes: B29C 66/91231 of the joining tool
• CPC Class Codes: B29C 66/91421 of the joining tools
• CPC Class Codes: B29C 66/91423 : using joining tools having different temperature zones or using several joining tools with different temperatures
• CPC Class Codes: B29C 66/91431 : the temperature being kept constant over time
• CPC Class Codes: B29C 66/91921 : in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
• CPC Class Codes: B29C 66/92 : by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
• CPC Class Codes: B29C 66/92211 : with special measurement means or methods
• CPC Class Codes: B29C 66/9241 : by controlling or regulating the pressure, the force or the mechanical power
• CPC Class Codes: B29C 66/9261 : by controlling or regulating the displacement of the joining tools
• CPC Class Codes: B29C 66/929 : characterized by specific pressure, force, mechanical power or displacement values or ranges
• CPC Class Codes: B29C 66/961 : involving a feedback loop mechanism, e.g. comparison with a desired value
• CPC Class Codes: B29C 66/967 : involving special data inputs or special data outputs, e.g. for monitoring purposes
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/065 : HDPE, i.e. high density polyethylene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29L 2023/22 : Tubes or pipes, i.e. rigid bent tubes not for use as pipe couplings B29L2023/004
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 38/0004 : Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 41/00 : Arrangements for controlling or monitoring lamination processes; Safety arrangements
• CPC Class Codes: Y10T 137/0318 : Processes
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal

Abstract

Disclosed is a method and apparatus for use in a fusion process for conduit. The method includes the steps of: removably positioning a first terminal edge of a first conduit portion with a first terminal edge of a second conduit portion; facing the terminal edges of the first conduit portion and the second conduit portion; aligning the terminal edges of the first conduit portion and the second conduit portion; melting at least a portion of the terminal edges of the first conduit portion and the second conduit portion; engaging the melted terminal edge of the first conduit portion with the melted terminal edge of the second conduit portion; maintaining pressure between the engaged terminal edges, thereby creating a fused joint area; and removing at least a portion of the resultant external bead extending around the fused joint area. A fusion apparatus for employing this method is also disclosed.

Claims

1. A method for fusing a first conduit portion to a second conduit portion, comprising the steps of:

(a) removably positioning a first terminal edge of the first conduit portion in an opposing relationship with a first terminal edge of the second conduit portion;

(b) facing the first terminal edge of the first conduit portion and the first terminal edge of the second conduit portion;

(c) aligning the first terminal edge of the first conduit portion with the first terminal edge of the second conduit portion;

(d) melting at least a portion of the first terminal edge of the first conduit portion and the first terminal edge of the second conduit portion;

(e) engaging the melted terminal edge of the first conduit portion with the melted terminal edge of the second conduit portion; and

(f) maintaining pressure between the engaged terminal edge of the first conduit portion and the terminal edge of the second conduit portion, thereby creating a fused joint area;

wherein at least one of the first conduit portion and the second conduit portion comprises a polyvinyl chloride material.

2. The method of claim 1, further comprising the step of removing at least a portion of a resultant external bead extending around the fused joint area.

3. The method of claim 1, further comprising the step of removing at least a portion of a resultant internal bead extending around the fused joint area.

4. The method of claim 1, further comprising the steps of:

removably positioning a second terminal edge of the first conduit portion in an opposing relationship with a first terminal edge of a subsequent conduit portion;

facing the second terminal edge of the first conduit portion and the first terminal edge of the subsequent conduit portion;

aligning the second terminal edge of the first conduit portion with the first terminal edge of the subsequent conduit portion;

melting at least a portion of the second terminal edge of the first conduit portion and the first terminal edge of the subsequent conduit portion;

engaging the melted terminal edge of the first conduit portion with the melted terminal edge of the subsequent conduit portion; and

maintaining pressure between the engaged terminal edge of the first conduit portion and the terminal edge of the subsequent conduit portion, thereby creating a subsequent fused joint area.

5. The method of claim 1, further comprising the steps of:

removably positioning a second terminal edge of the second conduit portion in an opposing relationship with a first terminal edge of a subsequent conduit portion;

facing the second terminal edge of the second conduit portion and the first terminal edge of the subsequent conduit portion;

aligning the second terminal edge of the second conduit portion with the first terminal edge of the subsequent conduit portion;

melting at least a portion of the second terminal edge of the second conduit portion and the first terminal edge of the subsequent conduit portion;

engaging the melted terminal edge of the second conduit portion with the melted terminal edge of the subsequent conduit portion; and

maintaining pressure between the engaged terminal edge of the second conduit portion and the terminal edge of the subsequent conduit portion, thereby creating a subsequent fused joint area.

6. The method of claim 1, wherein the facing step provides a substantially square face, perpendicular to a first conduit portion and a second conduit portion centerline.

7. The method of claim 1, wherein the aligning step includes aligning an outside diameter of the first conduit portion with an outside diameter of the second conduit portion.

8. The method of claim 1, wherein the melting step includes the simultaneous heating of both the terminal edge of the first conduit portion and the terminal edge of the second conduit portion.

9. The method of claim 1, wherein the gauge pressure for the engaging step is calculated utilizing the following formula:

10. The method of claim 9, wherein conduit surface area (pSa) in square inches is calculated utilizing the following formula:

11. The method of claim 10, wherein when a conduit area is 1.00 square inch, the gauge pressure is calculated utilizing the following formula:

12. The method of claim 11, wherein when pipe surface area (pSa), interfacial pressure (Ip) and cylinder area of machine (Ca) are known, the gauge pressure is calculated utilizing the following formula:

13. A fusion apparatus capable of performing the method of claim 1.

14. The fusion apparatus of claim 13, wherein the apparatus is substantially mobile and configured to be moved to an onsite location.

22. The fusion apparatus of claim 1, wherein the heater mechanism includes a plurality of heat zones positioned on a surface of the heater mechanism, such that each of the plurality of heat zones may exhibit a different temperature, thereby providing zone heating.

23. The fusion apparatus of claim 22, wherein the surface of the heater mechanism includes an upper and a lower heat zone.

24. The fusion apparatus of claim 22, wherein at least one of the plurality of heat zones is in communication with and controllable by a control mechanism.

25. The fusion apparatus of claim 24, wherein the control mechanism provides for at least one of manual, analog and digital control of at least one of the plurality of heat zones.

15. A fusion apparatus for fusing a first conduit portion to a second conduit portion, comprising:

a first clamping mechanism configured to engage and position the first conduit portion;

a second clamping mechanism configured to engage and position the second conduit portion;

a drive mechanism in operable communication with at least one of the first clamping mechanism and the second clamping mechanism and configured to drive at least one of the first clamping mechanism and the second clamping mechanism in a substantially longitudinal direction;

a facing mechanism positionable between a terminal edge of the first conduit portion and the terminal edge of the second conduit portion and configured to face at least one of the terminal edge of the first conduit portion and the terminal edge of the second conduit portion; and

a heater mechanism configured to melt at least one of the terminal edge of the first conduit portion and the terminal edge of the second conduit portion

wherein at least one of the first conduit portion and the second conduit portion comprises a polyvinyl chloride material.

16. The fusion apparatus of claim 15, wherein at least one of the first clamping mechanism and the second clamping mechanism is movable.

17. The fusion apparatus of claim 15, wherein the heater mechanism is movable.

18. The fusion apparatus of claim 15, wherein the heater mechanism comprises at least one of:

(i) a heating plate;

(ii) a plurality of heating plates; and

(iii) a dual-faced heating plate.

19. The fusion apparatus of claim 15, further comprising a control mechanism configured to at least one of:

(i) communicate with and control at least one of the first clamping mechanism, the second clamping mechanism, the drive mechanism, the facing mechanism, the heater mechanism and at least one measurement device; and

(ii) receive and process data signals from at least one component of the fusion apparatus.

20. The fusion apparatus of claim 19, wherein the control mechanism is configured to maintain a specified temperature at a surface of the heater mechanism.

21. The fusion apparatus of claim 19, wherein the control mechanism is configured to communicate with and receive one of analog and digital input from at least one measurement device and provide at least one of manual, analog and digital control of a heating temperature of the heater mechanism.

26. The fusion apparatus of claim 15, further comprising at least one measurement device in communication with at least one of the first clamping mechanism, the second clamping mechanism, the drive mechanism, the facing mechanism and the heater mechanism.

27. The fusion apparatus of claim 26, wherein the measurement device is configured to measure a heating surface of the heater mechanism.

28. The fusion apparatus of claim 27, wherein the measurement device is at least one of a thermometer and a pyrometer.

29. The fusion apparatus of claim 15, wherein the apparatus is substantially mobile and configured to be moved to an onsite location.

30. The fusion apparatus of claim 15, wherein the facing mechanism includes at least one blade portion.

31. The fusion apparatus of claim 30, wherein the at least one blade portion is a carbide-tipped blade element.

32. A fusion apparatus for fusing a first conduit portion to a second conduit portion, comprising:

means for removably positioning a first terminal edge of the first conduit portion in an opposing relationship with a first terminal edge of the second conduit portion;

means for facing the first terminal edge of the first conduit portion and the first terminal edge of the second conduit portion;

means for aligning the first terminal edge of the first conduit portion with the first terminal edge of the second conduit portion;

means for melting at least a portion of the first terminal edge of the first conduit portion and the first terminal edge of the second conduit portion;

means for engaging the melted terminal edge of the first conduit portion with the melted terminal edge of the second conduit portion; and

means for maintaining pressure between the engaged terminal edge of the first conduit portion and the terminal edge of the second conduit portion, thereby creating a fused joint area;

wherein at least one of the first conduit portion and the second conduit portion comprises a polyvinyl chloride material.