WELDABLE CONNECTING ELEMENT FOR CONNECTING OR JOINING THERMOPLATIC LINE ELEMENTS, AND A WELDING ASSEMBLY AND A METHOD FOR PRODUCING A WELDED CONNECTION

Abstract

The invention relates to a weldable connecting element 2 for connecting or joining thermo-plastic line elements 3. The connecting element 2 comprises: a thermoplastic body 4; at least one heating element 6, which is embedded in the body 4, wherein the heating element 6 serves to generate heat in a welding area 5 for welding the body 4 to the at least one line element 3. Furthermore, a joining control 12 is provided, which is configured to prohibit the welding operation and/or to interrupt the welding operation if the body 4 and the line element 3 are not joined correctly.

Claims

1. A weldable connecting element (2) for connecting or joining thermoplastic line elements (3), comprising: a thermoplastic body (4); at least one heating element (6), which is embedded in the body (4), wherein the heating element (6) serves to generate heat in a welding area (5) for welding the body (4) to the at least one line element (3), wherein a joining control (12) is provided, which is configured to prohibit the start of the welding operation and/or to interrupt the welding operation if the body (4) is not correctly joined with the line element (3).

2. The connecting element (2) according to claim 1, wherein the heating element (6) is configured in the form of a resistance heating wire (7), wherein the joining control (12) comprises an interruption (20) in the resistance heating wire (7) and a bridging element (21) for closing the interruption (20), wherein the bridging element (21) is arranged in the body (4) such that the interruption (20) is closed when the line element (3) is correctly joined with the connecting element (2).

3. The connecting element (2) according to claim 2, wherein a stop (11) is formed in the body (4), which stop (11) serves as an insertion limit for the line element (3), wherein the bridging element (21) is configured in the form of an electrically conductive spring element (23), which is arranged in the stop (11).

4. The connecting element (2) according to claim 2, wherein the bridging element (21) is configured in the form of an electrically conductive spring element (23), which is arranged at an inner jacket surface (27) of the welding area (5) and acts in the radial direction.

5. The connecting element (2) according to claim 2, wherein the bridging element (21) is formed by a conductive material strip (26), which can be applied on the line element (3), in particular that wherein a stop (11) is formed in the body (4), which stop (11) serves as an insertion limit for the line element (3) and has a first contact (24) and a second contact (25) offset in the circumferential direction, and the material strip (26) can be applied on the front side of the line element (3) and serves to electrically connect the first contact (24) to the second contact (25).

6. The connecting element (2) according to claim 1, wherein at least one shaped element (15), in particular a recess, is formed on the body (4), which shaped element (15) serves to accommodate a sensor (13, 19) of the joining control (12).

7. The connecting element (2) according to claim 1, wherein at least two shaped elements (15), in particular recesses, which are axially spaced apart from one another, are formed on the body (4), each of which serves to accommodate a sensor (13, 19) of the joining control (12).

8. A welding assembly (1) comprising: at least one thermoplastic line element (3); a connecting element (2), which has a thermoplastic body (4), wherein a heating element (6) is embedded in the body (4), which serves to generate heat in a welding area (5) for welding the body (4) to the at least one line element (3); a welding device (10) for welding the connecting element (2) to the at least one thermo-plastic line element (3); wherein a joining control (12) is provided, which is configured to prohibit the start of the welding operation and/or to interrupt the welding operation if the body (4) is not correctly joined with the line element (3).

9. The welding assembly (1) according to claim 8, wherein the joining control (12) comprises a sensor (13), which is arranged or can be arranged on the body (4) of the connecting element (2), and that wherein the joining control (12) comprises a sensor counter-element (14), which is arranged or can be arranged on the line element (3), wherein the sensor (13) can be coupled to the welding device (10), and the welding device (10) is configured to start and/or to carry out the welding operation dependent on a correct position of the sensor counter-element (14) relative to the sensor (13).

10. The welding assembly (1) according to claim 9, wherein a joining device (16) is formed, which serves to position the at least one line element (3) relative to the connecting element (2), and that wherein the joining control (12) comprises a sensor (13), which is arranged or can be arranged on the joining device (16), and wherein the joining control (12) comprises a sensor counter-element (14), which is arranged or can be arranged on the line element (3), wherein the sensor (13) can be coupled to the welding device (10), and the welding device (10) is configured to start and/or to carry out the welding operation dependent on a correct positioning of the sensor counter-element (14) relative to the sensor (13).

11. The welding assembly (1) according to claim 9, wherein the sensor (13) is configured in the form of an RFID module, and wherein the sensor counter-element (14) is configured in the form of an RFID tag.

12. The welding assembly (1) according to claim 9, wherein the sensor (13) is configured in the form of a Hall sensor, and wherein the sensor counter-element (14) is configured in the form of a magnet element.

13. The welding assembly (1) according to claim 9, wherein the sensor (13) is configured in the form of an optical sensor, and that wherein the sensor counter-element (14) is configured in the form of a reflector.

14. The welding assembly (1) according to claim 8, wherein the joining control (12) comprises an ultrasonic sensor (19), in particular that wherein the ultrasonic sensor (19) is coupled to the welding device (10).

15. The welding assembly (1) according to claim 8, wherein at least one shaped element (15), in particular a recess, is formed on the body (4), which shaped element (15) serves to accommodate the sensor (13, 19).

16. The welding assembly (1) according to claim 8, wherein at least two shaped elements (15), in particular recesses, which are axially spaced apart from one another, are formed on the body (4), each of which serves to accommodate the sensor (13, 19).

17. A method for connecting or joining thermoplastic line elements (3) with a connecting element (2), comprising the method steps: providing the at least one thermoplastic line element (3); providing the connecting element (2), which comprises a thermoplastic body (4), wherein a heating element (6) is embedded in the body (4), which heating element (6) serves to generate heat in a welding area (5) for welding the body (4) to the at least one line element (3); joining the connecting element (2) with the at least one thermoplastic line element (3); providing a welding device (10) for welding the connecting element (2) to the at least one thermoplastic line element (3); welding the connecting element (2) to the at least one thermoplastic line element (3) by generating heat in the welding area (5) by means of the welding device (10), wherein the welding operation is started or resumed only if a correct connection between the body (4) and the at least one thermoplastic line element (3) is determined by means of a joining control (12).

18. The method according to claim 17, wherein the joining control (12) establishes a connection in an interruption (20) of a resistance heating wire (7) if the line element (3) is correctly joined with the connecting element (2).

19. The method according to claim 18, wherein the welding device (10) detects an interruption (20) of the resistance heating wire (7) and issues an error message.

20. The method according to claim 19, wherein the joining control (12) comprises a sensor (13, 19), which is coupled to the welding device (10), wherein the correct connection of the connecting element (2) and the line element (3) is retrieved by the welding device (10) by means of the sensor (13, 19) before the start of the welding operation and/or during the welding operation.

Description

[0053] For the purpose of better understanding of the invention, it will be elucidated in more detail by means of the figures below.

[0054] These show in a respectively very simplified schematic representation:

[0055] FIG. 1 a sectional view of an exemplary embodiment of a connecting element with a sensor and a sensor counter-element;

[0056] FIG. 2 a sectional view of a further exemplary embodiment of a connecting element with a sensor and a sensor counter-element, wherein a joining device is provided;

[0057] FIG. 3 a sectional view of a further exemplary embodiment of a connecting element with an ultrasonic sensor;

[0058] FIG. 4 a sectional view of a further exemplary embodiment of a connecting element with a sensor built into the connecting element;

[0059] FIG. 5 a perspective detailed view of a further exemplary embodiment of a connecting element with a bridging element in the form of a spring element arranged in a web;

[0060] FIG. 6 a perspective detailed view of a further exemplary embodiment of a connecting element with a bridging element in the form of a material strip;

[0061] FIG. 7 a perspective detailed view of a further exemplary embodiment of a connecting element with a bridging element in the form of a spring element arranged in an inner jacket surface;

[0062] FIG. 8 a sectional view of a further exemplary embodiment of a connecting element with an ultrasonic sensor, which comprises a transmitter and a receiver arranged diagonally opposite.

[0063] First of all, it is to be noted that in the different embodiments described, equal parts are provided with equal reference numbers and/or equal component designations, where the disclosures contained in the entire description may be analogously transferred to equal parts with equal reference numbers and/or equal component designations. Moreover, the specifications of location, such as at the top, at the bottom, at the side, chosen in the description refer to the directly described and depicted figure and in case of a change of position, these specifications of location are to be analogously transferred to the new position.

[0064] FIG. 1 shows a first exemplary embodiment of a welding assembly 1 with a connecting element 2 for connecting line elements 3.

[0065] In the exemplary embodiment according to FIG. 1, the connecting element 2 is configured in the form of an electric welding socket, and the line elements 3 are configured in the form of pipelines.

[0066] As can be seen in FIG. 1, it may be provided that the connecting element 2 has a thermo-plastic body 4, in which a heating element 6 is arranged in a welding area 5. The heating element 6 may in particular be configured in the form of a resistance heating wire 7.

[0067] For example, it is conceivable that the connecting element 2 serves to connect two line elements 3 and hence, two welding areas 5 are formed in the body 4 of the connecting element 2.

[0068] In this regard, one of the welding areas 5 serves to weld the connecting element 2 to the first line element, and a second one of the welding areas 5 serves, in this regard, to weld the connecting element 2 to the second line element 3.

[0069] As can further be seen in FIG. 1, it may be provided that the heating element 6 has a first connection point 8 and a second connection point 9, each of which serves to connect to a welding device 10. The two connection points 8, 9 may be formed, as shown in FIG. 1, in the region of the two longitudinal ends of the connecting element 2, wherein both welding areas 5 can be heated simultaneously by means of the welding device 10.

[0070] Furthermore, it is also conceivable that for each welding area 5, a first connection point 8 and a second connection point 9 for the welding device 10 are formed. This makes possible that each of the two welding areas 5 can be heated individually and independently of each other, and a welded connection can be produced separately between the connecting element 2 and the first line element 3 and between the connecting element 2 and the second line element 3.

[0071] As can further be seen in FIG. 1, it may be provided that a stop 11 is formed on the body 4 of the connecting element 2, which stop 11 serves to correctly position the two line elements 3 in the connecting element 2. The stop 11 may be formed centrally in the connecting element 2.

[0072] Furthermore, a joining control 12 is formed, which is configured to prohibit the welding operation and/or to interrupt the welding operation if the body 4 and the line element 3 are not joined correctly.

[0073] As can be seen in the exemplary embodiment according to FIG. 1, it may be provided that the joining control 12 comprises a sensor 13 and a sensor counter-element 14. In particular, it may be provided that for each of the line elements 3, a separate sensor 13 and/or a separate sensor counter-element 14 is formed.

[0074] Furthermore, it may be provided that a shaped element 15 for accommodating the sensor 13 is formed on the body 4 of the connecting element 2. In particular, it may be provided that the shaped element 15 serves for an interlocking accommodation of the sensor 13, whereby the position of the sensor 13 can be exactly defined. In particular, it may be provided that the shaped element 15 tool is configured in the form of a recess. The sensor counter-element 14 may be applied on the line element 3.

[0075] Furthermore, it may be provided that the sensor or the sensors 13 are connected to the welding device 10, whereby a welding is made possible depending on the joining control 12. The sensor 13 may be formed such that it can detect a certain position of the sensor counter-element 14.

[0076] If the sensor 13 is configured in the form of an RFID module, it is conceivable, for example, that by means of the functionality of the RFID module, the distance from the sensor counter-element 14 in the form of an RFID tag can be determined. Thus, the relative position of the RFID module and the RFID tag relative to one another can be determined.

[0077] If the sensor 13 is configured in the form of an Hall sensor, it is conceivable, for example, that by means of the functionality of the Hall sensor, the distance from the sensor counter-element 14 in the form of a magnet element can be determined. Thus, the relative position of the Hall sensor and the magnet element relative to one another can be determined.

[0078] If the sensor 13 is configured in the form of an optical sensor, it may be provided, for example, that it detects if the sensor counter-element 14, which is configured in the form of a reflector, is located at a particular position.

[0079] The welding operation for joining the connecting element 2 with the line elements 3 may comprise the following method steps, wherein they may also be carried out in a different order.

[0080] In a first method step, it may be provided that the connecting element 2 and the line elements 3 are provided, wherein the line elements 3 may be prepared for being welded to the connecting element 2 in accordance with the known welding methods.

[0081] In a further method step, the welding device 10 is provided, wherein electrical connections between the welding device 10 are connected to the first connection point 8 and the second connection point 9. Furthermore, the sensors 13 may be arranged on the connecting element 2 on the shaped elements 15 provided therefor and also be coupled to the welding device 10.

[0082] Furthermore, the sensor counter-elements 14 may be arranged on the line elements 3 in accordance with the necessary insertion depth.

[0083] Subsequently, the line elements 3 may be joined with the connecting element 2. In this process, the line elements 3 can be inserted in the connecting element 2 until the line elements 3 abut on the stop 11.

[0084] By means of the sensors 13, it can be detected whether the line elements 3 are correctly joined with the connecting element 2, wherein the welding operation can be started and/or carried out based on this information.

[0085] In particular, it may be provided that the welding operation is only started if the correct position of the line elements 3 is detected by means of the sensors 13.

[0086] Furthermore, it is also conceivable that the correct position of the line elements 3 is detected during the welding operation by means of the sensors 13, and the welding operation is terminated if the line elements 3 move out of their correct position relative to the connecting element 2 during welding. As an alternative to this, it is of course also conceivable that the welding operation is not terminated but that the welding device 10 issues an alarm signal, so that an operator has the opportunity to correct the position of the line elements 3 relative to the connecting element 2. This opportunity to correct the position may last for a certain time period. If the line elements 3 are not put into their correct position relative to the connecting element 2 within this time, the welding operation may be terminated.

[0087] FIG. 2 shows a further and possibly independent embodiment of the welding assembly 1, wherein again, equal reference numbers/component designations are used for equal parts as before in FIG. 1. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIG. 1 preceding it.

[0088] As can be seen in FIG. 2, it may be provided that a joining device 16 is formed, which serves to accommodate the line elements 3 and/or the connecting element 2. The joining device 16 may comprise clamping elements 17, which serve to hold and/or position the line elements 3. Furthermore, the joining device 16 may comprise clamping elements 18, which serve to hold and/or of positioning the connecting element 2.

[0089] As can be seen in FIG. 2, it may be provided that the sensors 13 of the joining control 12 are each arranged on the clamping elements 17 for the line elements 3, wherein the function of the joining control 12 may take place mutatis mutandis to the exemplary embodiment of FIG. 1.

[0090] The exemplary embodiment described in FIG. 2 entails the advantage that the sensors 13 may remain fixedly on the joining device 16.

[0091] FIG. 3 shows a further and possibly independent embodiment of the welding assembly 1 wherein again, equal reference numbers and/or component designations are used for equal parts as in FIGS. 1 through 2 above. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 1 through 2 preceding it.

[0092] As can be seen in FIG. 3, it may be provided that the joining control 12 comprises one or multiple ultrasonic sensors 19, which may be arranged on corresponding shaped elements 15 on the connecting element 2. Using ultrasonic sensors 19 entails the advantage that they do not require a sensor counter-element 14 but that, given the correct positioning of the ultrasonic sensors 19, a correct connection between the connecting element 2 and the line elements 3 can be directly detected. Thus, it is not necessarily required when using such ultrasonic sensors 19 that the line elements 3 are provided with a sensor counter-element 14.

[0093] The ultrasonic sensors 19 may be arranged in the region of the stop 11 and serve to detect the wall thickness of the connecting element 2. As long as the line elements 3 are not correctly inserted into the connecting element 2, only the wall thickness of the connecting element 2 is detected. However, if the line elements 3 are correctly inserted into the connecting element 2, the ultrasonic sensor 19 detects a different wall thickness due to the wall thickness of the line elements 3, whereby a correct positioning of the line elements 3 relative to the connecting element 2 can be determined.

[0094] Instead of using two ultrasonic sensors 19, it is of course also conceivable that only one ultrasonic sensor 19 is formed, which may detect the correct positioning of the two line elements 3 relative to the connecting element 2 due to a larger detection area.

[0095] The individual ultrasonic sensors 19 may also be coupled to the welding device 10, in order to be able to carry out the welding dependent on the detection by the ultrasonic sensors 19.

[0096] Furthermore, it is also conceivable that the ultrasonic sensors 19 do not only serve to check the correct positioning of the connecting element 2 relative to the line elements 3, but that due to the changes in material properties in the connecting element 2 and/or in the line element 3, a correct progress of the welding can be detected, as well.

[0097] Here, as well, the ultrasonic sensors 19 may be removed from the connecting element 2 after conclusion of the welding process.

[0098] FIG. 4 shows a further and possibly independent embodiment of the welding assembly 1 wherein again, equal reference numbers and/or component designations are used for equal parts as in FIGS. 1 through 3 above. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 1 through 3 preceding it.

[0099] As can be seen in FIG. 4, it may be provided that the sensor 13, 19 is embedded in the connecting element 2 and remains fixedly in the same. In the exemplary embodiment according to FIG. 4, it is of course also possible that optionally one sensor 13, 19 or a separate sensor for each of the line elements 3 could be provided.

[0100] FIG. 5 shows a further and possibly independent embodiment of the welding assembly 1 wherein again, equal reference numbers and/or component designations are used for equal parts as in FIGS. 1 through 4 above. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 1 through 4 preceding it.

[0101] In FIG. 5, the connecting element 2 is shown in a perspective detailed view. Here, a detailed section from the vicinity of the stop 11 can be seen, in particular.

[0102] As can be seen from FIG. 5, it may be provided that the heating element 6, in particular the resistance heating wire 7, comprises an interruption 20. Furthermore, a bridging element 21 may be provided, which serves to bridge the interruption 20 and thus to close an electrically conductive connection in the heating element 6. In particular, it may be provided that the bridging element 21 is arranged on a front side 22 of the stop 11. Of course, it may be provided that on both front sides 22 of the stop 11, one such interruption 20 and/or a bridging element 21 each are formed, so that the correct joining of both line elements 3 can be detected.

[0103] As can be seen from FIG. 5, it may be provided that the bridging element 21 is configured in the form of a spring element 23, which forms a first contact 24 on its longitudinal end. Directly in the front side 22 of the stop 11, a second contact 25 may be formed. The second contact 25 is preferably configured such that it slightly protrudes relative to the front side 22 of the stop 11. In an un-installed state, the spring element 23 may be positioned in the stop 11, as shown in FIG. 4, such that the first contact 24 of the spring element 23 and the second contact 25 are spaced apart from one another. If the line element 3 is now inserted into the connecting element 2, a front side of the line element 3 pushes against the spring element 23, whereby the first contact 24 is pushed against the second contact 25. Thereby, the interruption 20 can be bridged in an electrically conductive manner, and the welding operation can be started.

[0104] Of course, it is conceivable that the spring element 23 is formed by a separate element, which is coupled to the resistance heating wire 7 in an electrically conductive manner. Alternatively, it is of course also conceivable that the spring element 23 is formed directly by the resistance heating wire 7.

[0105] FIG. 6 shows a further and possibly independent embodiment of the welding assembly 1 wherein again, equal reference numbers and/or component designations are used for equal parts as in FIGS. 1 through 5 above. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 1 through 5 preceding it.

[0106] As can be seen from FIG. 6, it may be provided that the resistance heating wire 7 forms the interruption 20 on the front side 22 of the stop 11. In this regard, the first contact 24 may be formed on a side of the interruption 20 of the resistance heating wire 7, and the second contact 25 may be formed on a second side of the interruption 20 of the resistance heating wire 7.

[0107] In this exemplary embodiment, a material strip 26 made from an electrically conductive material serves as a bridging element 21. The material strip 26 is applied to a front side of the line element 3 and establishes, in a correctly connected state of the connecting element 2 and the line elements 3, an electrically conductive connection in the interrupted resistance heating wire 7. The material strip 26 may, for example, extend over a front-side circumferential segment of the line element 3. Alternatively, it is also conceivable that the material strip 26 extends on the front side over the entire circumference of the line element 3.

[0108] In an alternative embodiment variant, which is not shown, it may also be provided that mutatis mutandis to the exemplary embodiment according to FIG. 5, the resistance heating wire 7 is interrupted, wherein the first contact 24 and the second contact 25 are formed. However, in this regard, it may be provided that the two contacts 24, 25 are arranged on an inner jacket surface 27 of the welding area 5. In correspondence therewith, it may be provided that the material strip 26 is arranged on an outer jacket surface 28 of the line element 3. In this exemplary embodiment, which is not shown, the connection of the interruption 20 is also closed by the material strip 26 of the connecting element 2 and the line element 3 are correctly joined together.

[0109] FIG. 7 shows a further and possibly independent embodiment of the welding assembly 1 wherein again, equal reference numbers and/or component designations are used for equal parts as in FIGS. 1 through 6 above. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 1 through 6 preceding it.

[0110] As can be seen from FIG. 7, it may be provided that the interruption 20 is formed in the region of the inner jacket surface 27 of the body 4. In this regard, it may be provided that the bridging element 21 has a structure similar to that of a contact switch. In particular, it may be provided that a contact element 29 is formed, which serves to rest on an outer jacket surface 28 of the line element 3. A part of the resistance heating wire 7, which part serves to create an electrically conductive bridging of the interruption 20, may be coupled to the contact element 29. Furthermore, a spring element 30 may be formed, which serves to open the contact on the interruption 20 as soon as the correct positioning of the connecting element 2 and the line elements 3 is disturbed.

[0111] FIG. 8 shows a further and possibly independent embodiment of the welding assembly 1 wherein again, equal reference numbers and/or component designations are used for equal parts as in FIGS. 1 through 7 above. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 1 through 7 preceding it.

[0112] As can be seen in FIG. 8, it may be provided that the ultrasonic sensor 19 of the joining control 12 comprises a transmitter 31 and a receiver 32, which are arranged diagonally opposite on the connecting element 2 and are simultaneously offset to one another. The transmitter 31 and the receiver 32 may, in this regard, be oriented to one another, such that both line elements 3 are located within the detection area of this ultrasonic sensor 19. Thus, the correct position of both line elements 3 can be determined with just one transmitter 31 and one receiver 32.

[0113] The exemplary embodiments show possible embodiment variants, and it should be noted in this respect that the invention is not restricted to these particular illustrated embodiment variants of it, but that rather also various combinations of the individual embodiment variants are possible and that this possibility of variation owing to the teaching for technical action provided by the present invention lies within the ability of the person skilled in the art in this technical field.

[0114] The scope of protection is determined by the claims. However, the description and the drawings are to be adduced for construing the claims. Individual features or feature combinations from the different exemplary embodiments shown and described may represent independent inventive solutions. The object underlying the independent inventive solutions may be gathered from the description.

[0115] All indications regarding ranges of values in the present description are to be understood such that these also comprise random and all partial ranges from it, for example, the indication 1 to 10 is to be understood such that it comprises all partial ranges based on the lower limit 1 and the upper limit 10, i.e. all partial ranges start with a lower limit of 1 or larger and end with an upper limit of 10 or less, for example 1 through 1.7, or 3.2 through 8.1, or 5.5 through 10.

[0116] Finally, as a matter of form, it should be noted that for ease of understanding of the structure, elements are partially not depicted to scale and/or are enlarged and/or are reduced in size.

LIST OF REFERENCE NUMBERS

[0117]

TABLE-US-00001  1 Welding assembly  2 Connecting element  3 Line element  4 Body  5 Welding area  6 Heating element  7 Resistance heating wire  8 First connection point  9 Second connection point 10 Welding device 11 Stop 12 Joining control 13 Sensor 14 Sensor counter-element 15 Shaped element 16 Joining device 17 Clamping element of the line element 18 Clamping element of the connecting element 19 Ultrasonic sensor 20 Interruption 21 Bridging element 22 Front side of the stop 23 Spring element 24 First contact 25 Second contact 26 Material strip 27 Inner jacket surface 28 Outer jacket surface of the line element 29 Contact element 30 Spring element 31 Transmitter 32 Receiver