NL2023343B1

NL2023343B1 - A water distribution manifold module, system and method for forming a module and method for modularly expanding a manifold.

Info

Publication number: NL2023343B1
Application number: NL2023343A
Authority: NL
Inventors: Matthias Janssen Stefan
Original assignee: Floorequa Holding B V
Priority date: 2019-06-19
Filing date: 2019-06-19
Publication date: 2021-01-28
Also published as: WO2020256552A1

Abstract

Title: A water distribution manifold module, system and method for forming a module and method for modularly expanding a manifold. Abstract A water distribution manifold module comprising: -a ﬁrst thermoplastic manifold body defining a first inner chamber, wherein the body comprises a ﬁrst end, a second end, and a plurality of side ports; - a ﬁrst thermoplastic support plate comprising a first face, and a second face, wherein a first through hole extends from the first face to the second face such that the first inner chamber is ﬂuidly accessible through the ﬁrst through hole; and - a ﬁrst mirror weld uniting the ﬁrst body at its first end and the first plate at its ﬁrst face.

Description

P122753NL00 Title: A water distribution manifold module, system and method for forming a module and method for modularly expanding a manifold.

The invention generally relates to a modular manifolds for water distribution systems. Water distribution manifolds are in a domestic and industrial setting known and used for, amongst other things, distributing water in heating networks. Most notably, such manifolds increasingly find application in hot water supply from a central source and floor heating networks. Typically, water manifolds used in floor heating networks are premade for a different application. Often such manifolds are metallic. Though arguably quite durable, such manifolds dissipate heat easily. This may reduce efficiency of a heating network, where heat is preferably dissipated by those tubes connected to the manifold serving as heat exchangers under the floor. In addition to heating networks, cooling networks may also comprise such metallic manifolds. In cooling networks heat dissipation through the manifold may cause condensate, which is undesirable. The typical manifold is fabricated off-site, shipped to the domicile and there installed. Once on-site, the site may prove to have a particular size and layout which may in hindsight require more than one manifold to be installed in series. Providing additional connections between manifolds often requires manifold to be refitted and reshipped from production locations far away or more vulnerable connections, such as hose connections are provided between manifolds . As such, there is a demand for water distribution manifolds which are readily adjustable in size. The invention aims to mitigate at least some of the mentioned drawbacks. In particular, the invention aims to provide a manifold module, a method for forming such a module, and methods for expanding such a manifold module and a water distribution system.

According to a first aspect of the invention a water distribution manifold module comprises a first thermoplastic manifold body defining a first inner chamber.

This first body 1s preferably a tubular body, to allow water pressure to be distributed equally along an inner surface of the first body.

The first body comprises a first end, a second end, and a plurality of side ports.

The module further comprises a first thermoplastic support plate comprising a first face, and a second face.

A first through hole extends from the first face to the second face such that the first inner chamber is fluidly accessible through the first through hole.

The module further comprises a first weld uniting the first body at its first end and the first plate at its first face.

It will be understood that water pipes and or tubes can be connected to the first body at the side ports.

Optionally, the second face of the first plate can be provided with a first fluid connection port which is fitted to the first through hole.

The module would receive water through the first through hole, and distribute this water over side ports and optionally the second end.

Any type of weld may be used, for example a socket weld, or a fillet weld.

Any of these welds may provide an easy obtainable and suitable connection between the elements, to achieve the benefits of the invention.

However, preferably but not exclusively, the weld that unites the first body and the first plate is a mirror weld.

To obtain a mirror weld, a pattern may be milled in the first face of the first plate.

The pattern may be of any suitable shape or include any kind of feature that enables to obtain a strong mirror weld.

For example, the pattern may provide the first face with an upstanding wall that is milled into the first face (e.g. by removing part of the plate material on either side of the upstanding wall). The upstanding wall may substantially have the shape and size of an edge of the first end of the first body.

A mirror weld may then be obtained by fusing the material of the upstanding wall with material of the first end, which will provide a very strong and easily obtainable weld.

A benefit of the integral nature of the mirror weld is that no crevasses exist through which leakage may occur.

As such the connection between the first plate and body is prevented from loosening in the process of frequent thermal expansion and contraction of parts. Optionally, the first mirror weld extends radially inward and outward with respect to the first body. The module is therefor thickest there were the first body and the first plate meet. This is advantageous to the physical integrity of the module. A further benefit is that this prevents the transition between an inner surface of the first body and the first face of the first wall to occur under an acute angle reducing material stresses.

Optionally, the first weld at least partially extends over the first through hole at the first face of the first plate. A benefit is that this allows any impurities, such as gas bubbles entrapped in the weld to be fluidly inaccessible in the connection between the first plate and a body. Further to this, a fitting can be provided to the first through hole, as well as any further through hole, such as to allow a fluid connection to be established there through to an associated inner chamber. A benefit of allowing the first weld to extend partially over the first through whole, and as such into a fluid path, is that this reduces the chance of leakage at or around an introduced fitting.

Optionally, the first thermoplastic manifold body and the first thermoplastic support plate are substantially made of any one of Polyethylene, Polypropylene and Polyvinyl chloride, Polyamide, Polyoxymethylene, High Molecular Polyethylene, Polytetrafluorethylene, Polyvinylidene fluoride, polyvinylidene difluoride, Polyethylene terephthalate, Polyetheretherketon, preferably polypropylene. A benefit to the use of these materials is that they provide thermal isolation across the module and allow for the safe and durable transport of warm water at standard floor heating temperatures of 30 - 60 °C, preferably 40-50°C (e.g. 45°C, 46°C, 47°C, 48°C, 49°C or 50°C) and at a pressure of 1.5 - 2 bar. Also the this option is beneficial for the transport of cooling water, wherein the formation of atmospheric water condensate is prevented on the module. In a cooling use cooling water of approximately 18°C can be heated by the environment to approximately 23°C in heat exchangers connected to the manifold module. However, the material is also suitable for operations under higher temperatures, such as temperatures in the range of 85 - 95°, such as may be the case in hot water supply from a central source (i.e. district heating or city heating) implementations. The thermoplastic nature of the module allows parts to be safely at temperatures below temperatures, namely at 210 °C, at which organic materials combust. This decreases the hazard of fire when a module is made, and when a module is expanded with another module through mirror welding.

The outer diameter to wall thickness ratio (SDR) of the first and/or second body of the module is preferably between 63/6 and 63/11, This enables the module to operate continuously at relatively high temperature such as 70°C, and is resistant for extended periods to temperatures up to and including 90°C. In one example the body has an outer diameter of 63 mm and a wall thickness of 10.5 mm (63/6).

Optionally, the first face and second face of the first plate are opposite faces. This beneficially allows modules to be linearly be connected end to end.

Optionally, the second plate is a mirror image of the first plate, wherein the second plate is either similarly provided with through holes. As such the second plate derives the same benefits as the first plate in its connection to a first and or second body. Optionally, the second plate is a mirror image of the first plate, wherein the second plate differs from the first plate in that the second plate is closed.

Optionally, at least one of the plurality of side ports of the first body is saddle welded to the first body. This allows the module to maintain structural integrity when exposed to higher water temperatures of around 70 — 95 °C while providing side ports. It is noted that operational temperature is preferably 30 - 60 °C, more preferably 40-50°C (e.g. 45°C, 46°C, 47°C, 48°C, 49°C or 50°C). Optionally the side ports are provided with a threaded fitting for connecting piping thereto. Optionally, the module comprises a second thermoplastic manifold 5 body defining a second inner chamber. This second body is preferably a tubular body, to allow water pressure to be distributed equally along an inner surface of the second body. The second body comprises a first end, a second end, and a plurality of side ports. A second through hole extends from the first face to the second face of the first thermoplastic support plate such that the second inner chamber is fluidly accessible through the second through hole. A second weld unites the second body at its first end and the first plate its first face. A benefit of this bi-manifold layout is that the same module may through a first body distribute water and through the second body receive water. In other words, the manifold can become dual purposed Preferably the second thermoplastic manifold body is substantially made of polypropylene. Optionally, the second face of the first plate can be provided with a second fluid connection port which is fitted to the second through hole. In combination with a first fluid connection port provided to the second face of the first plate and fitted to the first through hole, an inlet and outlet port can be defined for dual manifold purpose, namely water distribution via the first body, and water collection and return via the second body.

As explained hereinbefore, preferably but not exclusively and in accordance with some embodiments, the second weld 1s a second mirror weld. Optionally, the first mirror weld and second mirror weld are merged into a first unitary mirror weld. A benefit is that this allows the first and second welds to be thickest there where the first and second bodies are most proximate to each other. This provides additional structural integrity to the module.

Optionally, the first thermoplastic support plate comprises fastening elements, such as bore holes, for securing a pump to the second face of the first support plate in such a manner that the pump can fluidly interact with the first inner chamber of the first body and second inner chamber of the second body. A benefit is that this allows the module to serve as a primary manifold module to a pump, the first in a series of modules.

Optionally the second thermoplastic manifold body comprises a check valve. A benefit is that this prevents backflow of water leaving the pump. In an embodiment wherein both a first and second manifold body are present a first body can be used to transport water of a first temperature, and the second body can be used to transport water of a second temperature, wherein the first temperature is higher than the second temperature. More precisely, the first body expels water through side ports, wherein the second body collects water through the side ports. Optionally, the water that is expelled from the first body is water that is used to dissipate heat in an associated heat exchanger and is returned to and thus collected by the second body. The check valve here being arranged specifically in the first body, prevents back flow of the hotter water into the colder water, but allows the flow of colder water into the hotter water. This allows hot water to be cooled prior to being divided through the first manifold body. This increases the longevity of the module and allows it to receive water at temperatures which would otherwise be damaging. Such as water above 90°C, in particular between 90 — 120 °C. Preferably the check valve is places in the first body after the pump, upstream of any side ports. In one example water of 90°C - 120°C is received by the module, wherein the water of the second temperature is between 20 - 40°C and is mixed with the received water such that the water of the first temperature becomes 50° - 70°C. The upper operational temperature of the module in such a situation is that of the water of the first temperature.

Optionally, the module comprises a second thermoplastic support plate and a third mirror weld uniting the first body at its second end and the second plate, such as at its first face. A benefit is that this allows the module to serve as a terminal module in a series of modules. The second thermoplastic support plate can be provided without any through holes.

Optionally, the module comprises a fourth mirror weld uniting the second body at its second end and the second plate at its first face.

Optionally, the third mirror weld and the fourth mirror weld are merged into a second unitary mirror weld. This yields an increased structural integrity.

Optionally, the module is arranged for operating under a upper water pressure of 1 — 3 bar, preferably 1.5 — 2.5 bar, and an upper operational temperature of 30 — 55 degrees Celsius. Note that the upper operational temperature can be different from the temperature at which water is supplied to the module. In the case that the module is fitted with a check valve for example back mixing processes can reduce water of higher temperatures to temperatures within the above presented range. This 1s beneficial to the longevity of the module.

According to a further aspect of the invention a method is provided for forming a water distribution manifold module comprising the step of providing a first thermoplastic manifold body defining a first inner chamber. The first body comprises a first end, a second end, and a plurality of side ports. The method also comprises providing a first thermoplastic support plate comprising a first face and a second face. The second face being opposite the first face. The method further comprises uniting the first end of the first body with the first face of the first thermoplastic support plate by a first weld. Any type of weld may be used, for example a socket weld or a fillet weld. To form, in a preferred embodiment, the weld as a first mirror weld, the first face may comprise two recesses which define there between a first upstanding wall. The first upstanding wall has the shape and size of an edge of the first end of the first manifold body. A first through hole extends from the first face to the second face.

The method further comprises heating the first upstanding wall and the edge of the first end of the first body by means of a common heating element to a melting temperature between 200°C - 220°C.

The method further comprises pressing the heated first upstanding wall and the edge of the first end of the manifold first body together to form a first mirror weld.

The first through hole is here provided such that, after the pressing step, the first inner chamber is fluidly accessible through the first through hole.

Optionally, the heated parts are pressed together such that the first mirror weld extends radially inward and outward with respect to the first body.

Optionally, the first weld at least partially extends over the first through hole at the first face of the first plate.

A benefit is that this allows any impurities, such as gas bubbles entrapped in the weld to be fluidly inaccessible in the connection between the first plate and a body.

Optionally the method comprises the step of providing a second thermoplastic manifold body defining a second inner chamber.

The second body comprises a first end, a second end, and a plurality of side ports.

A second through hole extends from the first face to the second face of the first thermoplastic support plate such that the second inner chamber is fluidly accessible through the second through hole.

The first face comprises two further recesses which define a second upstanding wall.

The second upstanding wall has the shape and size of an edge of the first end of the second manifold body.

The method further comprising the step of heating the second upstanding wall and the edge of the first end of the second body by means of a common heating element to a melting temperature.

The method further comprising the step of pressing the heated second upstanding wall and the edge of the first end of the second body together to form a second mirror weld.

The second through hole is provided such, that after pressing the second inner chamber is fluidly accessible through the second through hole.

Optionally, the method comprises the step of providing the two recesses as concentric grooves, and providing the two further recesses as concentric grooves, such that the outer recess of the two recesses and the outer recess of the two further recesses overlap. A benefit is that this allows the welds to merge in the area between upstanding walls and increase structural integrity of a module.

Optionally, the surface of any face of any support plate, on which an upstanding wall can be identified, can be milled to a depth equal to a depth of those recesses defining there between such an upstanding wall. A benefit is that this prevents the formation of any impurities, such as gas bubbles in the weld.

Optionally, the method comprises the step of pressing the heated first upstanding wall and the edge of the first end of the first body together, and pressing the heated second upstanding wall and the edge of the first end of the second body, such that the first mirror weld and the second mirror weld merge into a first unitary mirror weld there were the outer recesses of the two further recesses overlap.

Optionally, the method comprises the step of providing a first water distribution manifold module according to a first aspect of the invention and providing a second water distribution manifold according to a first aspect of the invention. The method further comprising the step of providing an inter-modular mirror weld between at least the second end of the first body of the first module A and the second face of the first plate of the second module, such that the first chamber defined by the first body of the first module and the first chamber defined by the first body of the second module are fluidly connected through the first through hole of the first plate of the second module.

Optionally, the method comprises the step of providing a first water distribution manifold module according to a first aspect of the invention wherein a second body is comprised in the first module. The method also comprises the step of providing a second water distribution manifold module according to a first aspect of the invention wherein also a second body is comprised in the first module. The intermodular weld is in this option further provided between the second end of the second body of the first module, and the second face of the first plate of the second module, such that the second chamber defined by the second body of the first module and the second chamber defined by the second body of the second module are fluidly connected through the second through hole of the first plate of the second module.

Alternatively, a method for expanding a domestic, industrial or utility water distribution manifold comprising providing a first and second module, wherein the first module comprises a second thermoplastic support plate. This second support plate comprises a through hole, hereafter named the third through hole. The third through hole is provided such as to allow a fluid connection there through to the first inner chamber of the first body of the first module. The second support plate of the first module is provided at the third through hole with a socket welded connector which extends outward from the first module. Such a socket welded connector can be a hollow pipe nipple. The connector can be made of a thermoplastic material.

The connector which is provided at the third through hole is additionally socket welded to the first support plate of the second module at the first through hole of the first support plate of the second module. Beneficially the intermodular connection becomes accessible for inspection from outside of a system while being also steadily supported and shielded against outside force between two support plates.

Alternatively, two modules can also be connected by a connector. In such an alternative embodiment a first module comprises a second thermoplastic support plate, wherein this second support plate comprises two through holes, namely a third through hole, and a fourth through hole.

The third through hole is provided such as to allow a fluid connection there through to the first inner chamber of the first body of the first module. The fourth through hole is provided such as to allow a fluid connection there through to the second inner chamber of the second body of the first module. This second support plate is provided at each of the third and fourth through holes with a socket welded connector which extend outward from the module. These socket welded connectors can be hollow pipe nipples. These connectors can be a thermoplastic material. In intermodular connection the connector which is provided at the third through hole can additionally be socket welded to the first support plate of the second module at the first through hole of the first support plate of the second module. The connector which is provided at the fourth through hole can additionally be socket welded to the first support plate of the second module at the second through hole of the first support plate of the second module. Beneficially both intermodular connection become separately accessible for inspection from outside of a system.

According to another aspect of the invention a water distribution system 1s provided comprising at least one distribution manifold module according to the first aspect of the invention, and a pump, such as a positive displacement pump, fluidly connected to the at least one module.

The invention will be further elucidated on the basis of the drawing, in which: Fig. 1 shows a schematic view of a first embodiment of a water distribution manifold module; Fig. 2 shows a schematic view of a second embodiment of a water distribution manifold module; Fig. 3 shows a schematic view of a third embodiment of a water distribution manifold module; Fig. 4 shows a schematic view of a first embodiment of a water distribution system;

Fig. 5 shows a schematic view of a second embodiment of a water distribution system; Fig. 6 shows a schematic view of a third embodiment of a water distribution system; Fig. 7 shows a cross-sectional view part of a module; Fig. 8 shows a schematic view of a system comprising two manifold modules; Fig. 9A shows a schematic view of an alternative second plate; Fig. 9B shows a schematic view of an alternative intermodular connection; and Figs. 10A-D show a alternative first and second upstanding walls. Figure 1 shows a schematic view of a first embodiment of a water distribution manifold module 1 formed by a method. In this method a first thermoplastic manifold body 3 is provided, which is shaped as a tube and defines a first inner chamber 4. The first body has an inner diameter of

45.8mmm, and a tubular wall thickness of 8.6mm. The body 3 has a first end 5, a second end 7 and has a plurality of side ports 9. In this example side ports 9 are saddle welded to the first body 3 and provided with threading. The side ports are further provide perpendicular to a longitudinal direction L of the body 3. However, this is entirely optional. Further a first thermoplastic support plate 11 is provided. This first support plate 11 may be a rectangular plate having a first face 13 and an opposite second face 14. The first plate 11 has a thickness of 12 — 25mm, preferably 15 — 18 mm and. The first support plate 11 has a first through hole 23 that extends from the first face 13 to the second face 14. The first body 3 and the first plate 11 are in this example both of substantially the same thermoplastic material, namely Polypropylene, which enables welding of these elements by means of a first weld (e.g. a socket weld, fillet weld, mirror weld). However, other thermoplastic materials are also possible, such as Polyethylene, Polyamide, Polyoxymethylene, High Molecular Polyethylene, Polytetrafluorethylene,

Polyvinylidene fluoride, polyvinylidene difluoride, Polyethylene terephthalate, Polyetheretherketon, or Polyvinyl chloride. In this example a second thermoplastic support plate 111, of the same material as the first plate 111s also provided. However, this second plate is only necessary when the module 11s not required to distribute or pass along water through the second end 7. The second plate 111 in this sense is an end-cap, closing the first body at its second end 7. Other modules may not require to be closed at their second end, such as modules which are a connected to another module at their second end. To enable mirror welding, on the first face 13 of the first plate 11 a first set of two concentric grooves, also referred to as recesses, 15, 17 are provided which grooves define between them an upstanding wall 19. This upstanding wall 19 has substantially the shape and size of the edge of the first end 5 of the first body 3. The recesses have a depth of 5 mm, and a width of 4 mm. The upstanding body has a thickness of 8.6 mm. The two recesses 15, 17 are in this example carved into the first face 13 of the first plate 11 by drilling or by milling. However, other methods of providing the recesses are possible. The upstanding wall 19 and the edge of the first end 5 of the first body 3 are pressed for 2 — 4 minutes against the heating element and heated to their melting temperature, which is 1n this example 200 — 220 °C, against opposite surfaces of a common heating element (not shown, but customary). The heating element is removed and the first plate 11 and first body 3 are subsequently pressed together for 6 — 30 minutes with a pressure of 0.1 N/m? and allowed to cool such that a first mirror weld M1 forms of the first upstanding wall 19 and the edge of the first end 5 of the first body 3.

The first mirror weld M1 is under the pressing action allowed to flow both radially outwards and inwards with respect to the first body 3 such that the grooves 15, 17 of the first set of grooves are filled with molten material and the weld extends partially into the first inner chamber 4 of the first body 3. An inwardly directed ring-like part of the weld extends partially over the first through hole 23. Looking from the inside of the first body towards the first plate, one can see that the first plate is hereby either entirely covered or less exposed to water inside of the first body.

The first plate, prior to mirror welding, is indicated in Figure 1 with 11* and is shown in cross- section.

Bore holes 16 can be provided if so desired.

However other fastening features may alternatively be provided to the first wall 11 and can be used to provide a coupling interface such as for a pump.

In this example only two bore holes 16 are shown.

However, other numbers of bore holes are also possible and can be readily added using a drill.

The second support plate is also provided with a set of two concentric recesses which define there between a further upstanding edge.

Said upstanding edge and the end of the edge of the second end 7 of the first body 3 are also pressed and heated to their melting temperatures against opposite surfaces of the common heating element.

The heating element is removed and the second plate 111 and first body 3 are subsequently pressed together and allowed to cool such that a third mirror weld M3 forms of the further upstanding wall and the edge of the second end 7 of the first body 3. This third mirror weld forms a water tight seal between the first body and second plate.

The second support plate 111, prior to welding, only differs from the first plate 11 in that no through holes are provided therein.

Optional elements are identifiable in all Figures by their enclosure in dashed lines.

Figure 2 shows a schematic view of a second embodiment of a manifold module 1’ according to Figure 1. In the preceding Figure 1 and Figure 2 corresponding elements are provided with the same reference number.

Hereafter only differences between the module 1 of Figure 1 and the module 1’ of Figure 2 are discussed.

A second thermoplastic body 103, which 1s of the same thermoplastic material as the first body is provided.

The second body has a first end 105, a second end 107 and a plurality of side ports 109. In Figure 2 the second body 103 only differs from the first body 3 in that side ports are differently positioned along its length. However, this is merely to show that side ports 9, 109 may occupy different positions on different bodies 3, 103. In all other regards the second body 103 is identical to the first body 3. The first plate 11 is provided with a second through hole 123 which extends from the first face of the first plate to the second face of the first plate.

Additionally, the first plate 11%, as shown prior to any welding, is provided with a second set of two further recesses 15°, 17 which define there between a second upstanding wall 19’. The two further recesses 15’, 17’ are 1m this example also concentrically shaped and are provided such that the second upstanding wall 19’ has substantially the shape and size of the edge of the first end 105 of the second body 103. The two further recesses 15’, 17° are further provided such that the second upstanding wall 19° surrounds the second through hole 123 on the first face 13 of the first plate 11. The second upstanding wall 19’ and the edge of the first end 105 of the second body 103 are pressed and heated against opposite sides of the common heating element. The common heating element is removed and the heated second upstanding wall 19’. Under the pressing action the heated parts merge and are allowed to cool forming the second mirror weld M2. It is pointed out for completeness sake that while providing the second mirror weld M2 the melted material also flows in radially outward and inward directions with respect to the second body 103 causing the mirror weld M2 to extend partly into the second inner chamber 104 of the second body 103. The first and second mirror welds are in this example formed in the same manner and under the same conditions simultaneously. Optionally, these mirror welds can be formed in the same manner under the same conditions separately, such as in the event that an end cap, namely the second support plate, is not provided to the module 1’.

The second support plate 111 is, similar to the first plate 11, provided by another set of two recesses which define there between yet another upstanding edge.

Said upstanding edge and the end of the edge of the second end 107 of the second body 103 are also pressed and heated to their melting temperatures against opposite surfaces of the common heating element.

The heating element is removed and the second plate 111 and second body 103 are subsequently pressed together and allowed to cool such that a third mirror weld M4 forms of the concerning upstanding wall and the edge of the second end 107 of the second body 103. This fourth mirror weld M4 forms a water tight seal between the second body 103 and second plate 111. The third and fourth welds M3, M4 are in this example simultaneously formed.

Figure 3 shows a schematic view of a third embodiment of a manifold module 1” according to Figure 2. In the preceding Figure 2 and Figure 3 corresponding elements are provided with the same reference number.

Hereafter only differences between the module 1’ of Figure 2 and the module 1’ of Figure 3 are discussed.

In this example the first face 14 of the first plate 11 is provided with a first set of concentric recesses 15, 17 defining there between the first upstanding wall 19, and a second set of concentric recesses 15’, 17° defining there between the second upstanding wall 19°. The first and second set of recesses are provided such that the outer recess of each of the first and second set 15, 15’ overlap.

In this example the first wall 19 and second wall 19’ are spaced apart the width of one outer recess 15, 15’. This is however optional.

The width of the outer recesses here being equal in size.

The overlap between the outer recesses 15, 15’ allows the first mirror weld M1 and the second mirror weld M2 to merge, during the formation thereof, into a first unitary mirror weld M12. Due to the overlapping recesses 15, 15’ molten material forming both the first and second weld M1, M2 can freely flow into the recess uniting both welds.

In this example the entirely optional end cap is also shown in the form of the second plate 111. The second plate prior to welding 111% is also shown in Figure 3.

The first face of the second plate 111 is here provided with a third set of concentric recesses defining there between a third upstanding wall, and a fourth set of concentric recesses defining there between the fourth upstanding wall. The third and fourth set of recesses are provided such that the outer recess of each of the third and fourth set overlap. These sets as well as their defined upstanding wall are not shown. However these are identical to the recesses provided on the first face of the first plate. In this example the third wall and fourth wall are thus also spaced apart the width of one outer recess of the third and fourth set of recesses. The overlap between these recesses allows the third mirror weld M3 and the fourth mirror weld M4 to merge, during the formation thereof, into a second unitary mirror weld M34. Here too molten material forming both the third and fourth weld M3, M4 can freely flow into the area of overlap of the recesses to form a second unitary mirror weld M34.

Figure 7 shows in more detail the third and fourth mirror weld forming the second unitary mirror weld M34.

Figure 4 shows a schematic view of a water distribution system X according to another aspect of the invention. Figure 4 also portrays a fourth embodiment of a manifold module 1” according to Figure 3. In the preceding Figure 3 and Figure 4 corresponding elements are provided with the same reference number. Hereafter only differences between the module 1” of Figure 3 and the module 1” of Figure 4 are discussed. In this example the pump P is a positive displacement pump with an inlet and an outlet. The pump is secured to the second face 14 of the first plate 11. In particular the pump is fastened in a fluid tight manner by bolts which have been screwed into the bore holes 16. In this example four bore holes are provided for securing the pump to the first plate 11. The pump is designed such that the inlet of the pump aligns with the first through hole 23, and is thus in fluid communication with the second inner chamber 104 of the second body 103.

The pump is further designed such that the outlet of the pump aligns with the second through hole 123, such that the outlet of the pump 1s in fluid communication with the first inner chamber 4 of the first body 3.

It 1s here pointed out that any module which does not comprise a second body, can exclusively be fluidly connected to an inlet or an outlet of a pump via the first plate 11 thereof.

Figure 5 shows a schematic view of another embodiment of the water distribution system X’ according to Figure 4. In the preceding Figure 4 and Figure 5 corresponding elements are provided with the same reference number. Hereafter only differences between the system X of Figure 4 and the system X of Figure 5 are discussed. Figure 5 also portrays the embodiment of a fifth embodiment of a manifold module 17” according to Figure 4. Hereafter only differences between the module 1” of Figure 4 and the module 17” of Figure 5 are discussed. The first body 11 is fitted with a check valve CV.

Figure 6 shows a schematic view of another embodiment of the water distribution system X” according to Figure 5. In the preceding Figure 5 and Figure 6 corresponding elements are provided with the same reference number. Hereafter only differences between the system X’ of Figure 5 and the system X” of Figure 6 are discussed. In this example the pump P and a first module A are provided. In this example the first module A is the same module 1” as shown in Figure 5. A second module B is further also provided. The second module B is in this example a module 1” as shown in Figure 3. The first module A and second module B may alternatively also be represented by other embodiments.

In the method of expanding the manifold the following steps can be identified.

Providing on the second face 14 of the first plate 11 of the second module B a fifth set of concentric recesses 15”, 17” defining there between a third upstanding wall 19”, and a sixth set of concentric recesses 15”, 17” defining there between a fourth upstanding wall 19”. The fifth and sixth set of recesses are provided such that the outer recess of each of the fifth and sixth set 15”, 15” overlap.

In principle the fifth and six set of recesses are provided to mirror the first and second set of recesses provided on the first face of the first plate of the second module B.

The third and fourth upstanding wall are heated to a melting temperature on a first side of a mirror heating element.

The edge of the second end and first body as well as the edge of the second end of the second body of the first module A are heated to their melting temperature on a second side of the same mirror heating element.

The heating element is removed.

The heated edges and upstanding walls are pressed together and allowed to cool to form an mtermodular weld IM.

The intermodular weld is provided such that it mirrors the first and second welds M1, M2. Figure 8 shows a schematic view of a system comprising two manifold modules 1A, 1B according to the manifold module 1 as shown in Figure 1. In the preceding Figure 1 and Figure 8 corresponding elements are provided with the same reference number.

In this example Module 1A is connected, at a second face of a first support plate thereof, to a fluid outlet part of pump P.

Module 1B is connected, at a second face of a first support plate thereof, to a fluid inlet part of pump P.

Figure 9A shows a schematic view of an alternative second plate 111° to the second plate 111 according to Figure 2. In the preceding Figure 2 and Figure 9A corresponding elements are provided with the same reference number.

Hereafter only differences between the second plate 111 of Figure 2 and the second plate 111’ of Figure 9A are discussed.

In Figure 9A the second support plate 111’ comprises a third through hole 35, and a fourth through hole 37. The third through hole is provided such as to allow a fluid connection there through to the first inner chamber of the first body of the module 1’. The fourth through hole is provided such as to allow a fluid connection there through to the second inner chamber of the second body of the module 1’. The second support plate 111 is in this example provided at each of the third and fourth through holes with a socket welded connector 33. Each connector 33 extends outward and away from the first module A.

Figure 9B shows a schematic view of an alternative intermodular connection IM’ to the intermodular mirror weld IM of system X” shown in Figure 6. In the preceding Figure 6 and Figure 9B corresponding elements are provided with the same reference number.

Hereafter only differences between the intermodular mirror weld of Figure 6 and the intermodular connection IM of Figure 9B are discussed.

In Figure 9B the intermodular connection IM’ is formed by the following steps.

A first water distribution manifold module A is provided and a second water distribution manifold B is provided.

The first module A comprises a second thermoplastic support plate 111. This second support plate comprises a third through hole 35, and a fourth through hole 37. The third through hole 35 is provided such as to allow a fluid connection there through to the first inner chamber 4 of the first body 3 of the first module A.

The fourth through hole 37 is provided such as to allow a fluid connection there through to the second inner chamber 104 of the second body 103 of the first module A.

The second support plate 111’ of the first module A is provided at each of the third and fourth through holes with a socket welded connector 33. These connectors 33 extend outward from the first module A, in this example parallel to the length direction of the first module A.

The connector which is provided at the third through hole is additionally socket welded to the first support plate of the second module B at the first through hole 23 of the first support plate 11 of the second module B.

The connector which is provided at the fourth through hole is additionally socket welded to the first support plate of the second module B at the second through hole 123 of the first support plate 11 of the second module B forming an intermodular connection.

Alternatively, socket welded fittings may be provided at the third and fourth through holes of first module A and additional socket welded fittings may be provided at the first through hole 23 and second through hole 123 of first support plate 11 of second module B, after which the socket welded fittings are joint via connectors. Figure 10A shows a schematic view of an alternative first thermoplastic support plate 11* prior to welding for any of the previously discussed modules with first and second bodies 3, 103. In the preceding Figures and Figure 10A corresponding elements are provided with the same reference number. Hereafter only differences are discussed. In this example the surface of the first face 13, which is not defined by the first and second upstanding walls is milled to a depth D matching the depth of the first recess, which is in this example 5 mm, but may differ depending on the depth of the first recess. As such, any recesses which previously defined the upstanding walls are in this example no longer visible. It will be understood that in an alternative method the step of providing first and second recesses and the milling the mentioned surface to depth D can occur simultaneously in a single surface milling step. In such a step the first and second recesses are merely imaginary. The second support plate can be a mirrored or inverted first support plate as can be seen in Figure 10C. Optionally, the second support plate of Figure 10C can be entirely closed, in that it does not comprise any through openings, as can be seen in Figure 10D.

Figure 10B shows a schematic view of an alternative first thermoplastic support plate 11* prior to welding for the previously discussed module of Figure 6 In the preceding Figure 6 and Figure 10B corresponding elements are provided with the same reference number. In Figure 10B the surface of the first face 13, which is not defined by the first and second upstanding walls is also milled to a depth D matching the depth of the first recess, which is in this example 5 mm, but may differ depending on the depth of the first recess. The surface of the second face 14 of the first upstanding wall 11* which is not defined by upstanding walls 19” and 19” is similarly also milled to a depth D matching the depth of the concerning recesses, which is in this example 5 mm, but may differ depending on the depth of the first recess. It will also here be understood that in an alternative method the step of providing recesses and the milling the mentioned surfaces to depth D can each occur simultaneously in a single milling step.

As such there is at least described herein a water distribution manifold module comprising: -a first thermoplastic manifold body defining a first inner chamber, wherein the body comprises a first end, a second end, and a plurality of side ports; - a first thermoplastic support plate comprising a first face, and a second face, wherein a first through hole extends from the first face to the second face such that the first inner chamber is fluidly accessible through the first through hole; and - a first mirror weld uniting the first body at its first end and the first plate at its first face.

Claims

A water distribution manifold module (1) comprising: - a first thermoplastic manifold body (3) defining a first inner chamber (4), the first body (3) comprising a first end (5) having a rim, a second end (7) ) and a plurality of side openings (9); - a first thermoplastic backing plate (11) comprising a first side (13) and a second side (14), a first through hole (23) extending from the first side to the second side such that the first inner chamber (4) is fluidically accessible through the first through hole (23); and - a first weld (M1) joining the first body (3) at the first end (5) and the first plate (11) at the first side (13) in which the first weld (M1) a mirror weld is obtained by mirror welding the edge of the first end (5) onto a pattern provided on the first side (13), the pattern being of similar shape and size to the edge.

The module of claim 1, wherein the first weld is a first mirror weld 1s.

The module of claim 2, wherein the first mirror weld (M1) extends radially inwardly from the first body (3), optionally the weld extending at least partially across the first through hole (23) at the first. side (13) of the first plate (11).

The module according to any of the preceding claims, wherein at least one of the plurality of side openings (9) of the first body (3) is saddle welded to the first body (3) and is optionally provided with a threaded fitting.

The module of any of claims 2-4, further comprising: - a second thermoplastic manifold body (103) defining a second inner chamber (104), the second body (103) having a first white end (105), a second end (107) and includes a plurality of side openings (109); wherein a second through-hole (123) extends from the first side (13) to the second side (14) of the first thermoplastic backing plate (11), such that the second inner chamber (104) is fluidically accessible through the second through-hole ( 123), and wherein a second weld (M2) joins the second body (103) at the first end (105) and the first plate (11) at the first side, and preferably wherein the second thermoplastic manifold body (103) is substantially made of polypropylene, and optionally wherein the second mirror seal (M2) extends radially inwardly of the second body (103), optionally the second seal (M2) extends at least partially over the second through-opening ( 123) on the first side (13) of the first plate (11).

The module of claim 5, wherein the second weld is a second mirror weld.

The module of claim 6, wherein the first mirror weld (M1) and second mirror weld (M2) are provided to form a first common mirror weld (M12) in which part of the first end (5) of the first body (3) and the first end (103) of the second body (105) are fused together.

The module according to at least one of claims 5-7, wherein the first thermoplastic backing plate comprises mounting elements (16), such as boreholes, for mounting a pump (P) on the second side (14) of the first backing plate, preferably such that the pump fluidically interacts with the first inner chamber (4) of the first body (3) and with the second inner chamber (104) of the second body (103), optionally with the second thermoplastic manifold (103) having a non-return valve (CV).

The module of any one of the preceding claims, comprising - a second thermoplastic backing plate (111); and - a third weld (M3) joining the first body (3) at its second end (7) and the second plate (111), the third weld (M3) being a mirror weld.

The module according to at least claims 5 and 9, comprising - a fourth weld (M4) joining the second body (103) at its second end (107) and the second plate (111), wherein the fourth weld (M4) a mirror weld 1s wherein optionally the third mirror weld (M3) and the fourth mirror weld (M4) are arranged to form a second common mirror weld (M34), part of the second end (7) of the first body (3) and the second end (107) of the second body (105) are fused together.

The module according to any one of the preceding claims, wherein the module is arranged to operate under a water pressure of 1.5-2 bar and a temperature of 30-55 degrees Celsius.

A method of forming a water distribution manifold module (1) comprising the steps of: - providing a first thermoplastic manifold (3) defining a first inner chamber (4), the first body (3) including a first end ( 5) provided with a rim, a second end (7) and a plurality of side openings (9); - providing a first thermoplastic support plate (11) comprising a first side (13), - joining the first end (5) of the first body (3) with the first side (13) of the first thermoplastic support plate (11) ) through a first weld, wherein the first weld is a mirror weld obtained by providing a pattern on the first side (13), wherein the pattern of corresponding shape and size is as the edge of the first end (5), and mirror welding the edge to the pattern.

A method according to claim 12, wherein the first side comprises a first upright wall (19) optionally defined between two recesses (15, 17), the first upright wall (19) having the shape and size of an edge of the first end (5) of the first manifold (3) and a second face (14) opposite the first face (13), a first through-opening (23) extending from the first side to the second side; and - heating the first upright wall (19) and the edge of the first u end (5) of the first body by means of a common heating element to a melting temperature; - compressing the heated first upright wall (19) and the edge of the first end (5) of the first manifold body (3) to form the first weld as a first mirror weld (M1), the first continuous opening is provided such that upon compression, the first inner chamber (4) is fluidically accessible through the first through-opening (23).

The method of claim 12 or 13, comprising the steps of: - providing a second thermoplastic manifold body (103) defining a second inner chamber (104), the second body (103) comprising a first end (105), a second end (107) and a plurality of side pin openings (109); wherein a second through hole (123) extends from the first side (13) to the second side (14) of the first thermoplastic backing sheet (11) such that the second inner chamber (104) is fluidically accessible through the second through hole ( 123), wherein the first face includes a second upright wall (19 °) optionally defined between two further recesses (15 °, 17), the second upright wall having the shape and size of an edge of the first white end (105) of the second divider (103),

- heating the second upright wall and the edge of the first end (105) of the second body (103) by means of a common heating element to a melting temperature; - compressing the heated second upright wall (19) and the edge of the first end (105) of the second body (3) to form a second mirror weld (M2), the second through-opening (123) being such provides that upon compression, the second inner chamber (4) is fluidically accessible through the second through-hole (123).

The method according to claims 13 and 14, comprising the steps of: - compressing the heated first upright wall (19) and the edge of the first end (5) of the first body (3), and compressing the the heated second upright wall (19 ') and the edge of the first end (105) of the second body (3), such that the first mirror weld (M1) and the second mirror weld (M2) fuse into a first mirror weld unit (M12) .

The method of claim 15, comprising the step of: - providing the two recesses (15, 17) as concentric grooves, and providing two further recesses (15 ', 17') as concentric grooves, such that the outer recess (15) of the two recesses (15, 17) and the outermost recess (15 ') of the two further recesses (15', 17 ") overlap,

A method of expanding a water distribution manifold comprising the steps of: - providing a first water distribution manifold module (A) according to at least claim 1;

- providing a second water distribution manifold module (B) according to at least claim 1; - providing an intermodular splice (IM) between at least: - the second end (7) of the first body (3) of the first module (A); and - the second side of the first plate of the second module (B), such that the first chamber defined by the first body of the first module (A) and the first chamber defined by the first body of the second module (B) fluidically connected through the first through hole of the first plate of the second module (B).

The method of claim 17, wherein the first water distribution manifold module (A) according to at least claim 51s, and wherein the second module (B) according to at least claim 51s, wherein the intermodular weld IM) is further provided between: second end (107) of the second body (103) of the first module (A); and - the second side of the first plate of the second module (B), such that the second chamber defined by the second body of the first module (A) and the second chamber defined by the second body of the second module (B) fluidically connected through the second through hole of the first plate of the second module (B).

A method of expanding a water distribution manifold comprising the steps of: - providing a first water distribution manifold module (A) according to at least claim 1; - providing a second water distribution manifold module (B) according to at least claim 1;

wherein the first module comprises a second thermoplastic backing plate, said second backing plate including a third through-opening, the third through-opening being provided for releasing fluid communication therethrough to the first inner chamber of the first body of the first module, providing the second support plate of the first module (A) at the third through-opening with a melt-welded connector (33) extending outwardly from the first module (A), the connector provided at the third through-opening further is jointed with the first support plate of the second module (B) at the first through-opening of the first support plate of the second module.

A method of expanding a water distribution manifold, comprising the steps of: - providing a first water distribution manifold module (A) according to at least claim 5; - providing a second water distribution manifold (B) according to at least claim 5; wherein the first module comprises a second thermoplastic backing plate, said second backing plate including a third through-opening, and a fourth through-opening, the third through-opening being provided such that fluid communication therethrough to the first inner chamber of the first body of the first module, wherein the fourth through-opening is arranged to permit fluid communication therethrough to the second inner chamber of the second body of the first module, - providing the second support plate, of the first module (A) at each of the the third and fourth through-openings, with a muffled connector (33) which connectors extend outwardly from the first module (A), the connector disposed at the third through-opening being further weld-welded to the first support plate of the second module (B) at the first through-opening of the first support plate of the second module, and where the connector provided at the fourth through opening is further joint welded to the first support plate of the second module (B) at the second through opening of the first support plate of the second module.

A water distribution system comprising: - at least one distribution manifold module (1) according to any one of the preceding claims 1-11; and - a pump, such as a positive displacement pump, fluidically connected to the at least one module (1).