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Title:
PIPE BRANCH CONNECTOR
Document Type and Number:
WIPO Patent Application WO/2021/111126
Kind Code:
A1
Abstract:
A branch connector for connecting to a pipe for forming a branched pipe having a tube with a seating portion at an end of the tube, wherein the seating portion (204) comprises an arcuate surface for connecting to a pipe or cylinder. A method for constructing branched pipes using the branch connectors includes determining an opening position in the wall of the pipe, locating the branch connector over the opening position, and sealing the branch connector to the pipe around the opening position.

Inventors:
WEBB DARREN VIRGIL (GB)
Application Number:
PCT/GB2020/053085
Publication Date:
June 10, 2021
Filing Date:
December 02, 2020
Export Citation:
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Assignee:
POLYPIPE LTD (GB)
International Classes:
F16L41/08; F16L47/28
Domestic Patent References:
WO2015067574A12015-05-14
WO2003076840A12003-09-18
Foreign References:
DE20218378U12003-02-13
Attorney, Agent or Firm:
OXLEY, Robin John George (GB)
Download PDF:
Claims:
CLAIMS:

1. A branch connector for connecting to a pipe for forming a branched pipe, the branch connector comprising: a tube having a seating portion at an end of the tube, wherein the seating portion comprises an arcuate surface for connecting to a pipe or cylinder.

2 The branch connector according to claim 1, wherein the arcuate surface forms and/or defines a partial cylinder shape.

3. The branch connector according to any one of the preceding claims, wherein the arcuate surface forms less than half of a cylinder shape and/or extends around 180 degrees or less.

4. The branch connector according to any one of the preceding claims, wherein the arcuate surface has a radius configured so that the seating portion conforms to the surface of a 56mm, 75mm, 82mm, 110mm or 160mm diameter soil pipe.

5. The branch connector according to any one of the preceding claims, wherein the seating portion comprises a first arcuate surface and a second arcuate surface, wherein the first and second arcuate surfaces have a different size, shape, and/or curve radius.

6. The branch connector according to any one of the preceding claims, wherein the seating portion comprises a flange extending around the circumference or perimeter of the tube, said flange comprising at least part of the arcuate surface.

7. The branch connector according to claim 6, wherein the flange comprises a heating wire for use in an electrofusion welding process, and optionally wherein the branch connector further comprises at least one electrical connector for connecting the heating wire to a power source.

8. The branch connector according to any one of the preceding claims, further comprising a pipe connector portion for connecting to a further pipe or tube, and wherein the pipe connector portion is provided at an end of the tube opposite to the seating portion.

9. The branch connector according to any one of the preceding claims formed from HDPE, PVC-u or polypropylene.

10. A kit of parts comprising at least one branch connector according to any one of the preceding claims, and an elongate pipe.

11. The kit of parts according to claim 10, wherein the pipe is a 56mm, 75mm, 82mm, 110mm or 160mm diameter soil pipe.

12. The kit of parts according to claim 10 or claim 11, wherein the pipe is formed from HDPE, PVC-u or polypropylene.

13. A method for constructing a branched pipe, the method comprising: providing an elongate pipe and at least one branch connector according to any one of claims 1 to 9, determining an opening position in the wall of the pipe, locating the branch connector over the opening position, and sealing the branch connector to the pipe around the opening position.

14. The method according to claim 13, further comprising forming an opening through the wall of the pipe in the opening position.

15. The method according to claim 14, wherein forming the opening through the wall of the pipe is carried out prior to locating the branch connector over the opening position and sealing the branch connector to the pipe around the opening position.

16. The method according to claim 14, wherein forming an opening through the wall of the pipe is carried out after locating the branch connector over the opening position and sealing the branch connector to the pipe around the opening position.

17. The method according to any one of claims 14 to 16, wherein forming an opening through the wall of the pipe comprises cutting, laser cutting, milling, or drilling an opening extending through the thickness of the wall.

18. The method according to any one of claims 13 to 17, wherein the branched pipe is a soil stack pipe, and optionally, an 110mm diameter soil pipe.

19. The method according to any one of the preceding claims, wherein the elongate pipe is formed from HDPE, PVC-u, or polypropylene.

20. The method according to any one of the preceding claims, wherein the seating portion comprises a flange, the flange extending around the circumference and/or outer perimeter of the opening position.

21. The method according to any one of claims 13 to 20, wherein sealing the branch connector to the pipe around the opening position comprises making a fluid-tight seal.

22. The method according to any one of claims 13 to 21, wherein sealing the branch connector to the pipe comprises any one or more of: butt welding, electrofusion welding, induction welding, solvent welding, ultrasonic welding, RF welding, IR welding, friction welding, adhesion with an adhesive, or one or more mechanical fasteners.

23. The method according to any one of claims 13 to 22, wherein the opening has a circular, oval, or tear-drop shaped cross-section in an axis perpendicular to the axis of the elongate pipe.

24. The method according to any one of claims 13 to 23, further comprising providing a second branch connector according to claims 1 to 9, determining a second opening position in the wall of the pipe, locating the second branch connector over the second opening position, and sealing the second branch connector to the pipe around the second opening position.

25. A branched pipe formed by the method according to any one of claims 13 to 24.

Description:
Pipe Branch Connector

Technical Field

The following invention relates to the field of pipes and pipe connectors. More specifically, the invention relates to a method of constructing soil pipes for buildings.

Background

In both domestic and industrial buildings there is a requirement to remove both sewage (soil) and grey water and to feed such waste into the sewer network. Typically, this is achieved by a drain-waste-vent system, a major component of which is the soil stack. A soil stack is a large diameter vertical pipe which can be installed inside a building, either exposed or often within ducts, or as in more common in domestic buildings they could be installed on the outside of the building. The soil stack connects to the sewer at or below ground level, and is terminated at the uppermost end by a vent cowl above the roof level.

The soil vertical stack is provided as a common waste pipe to which the other soil and grey water pipes from the building feed into. A typical soil pipe will thus have multiple connections positioned at various heights to connect with the rest of the building’s waste water plumbing.

The drainage plumbing of each building is often unique and thus it is necessary to provide a high level of adaptability or configurability for a soil stack. Existing soil stacks are formed in situ from a variety of preformed branched pipe sections, bends and connectors which are connected to one another either directly or via straight lengths of soil pipe. All of these components are available ‘off the shelf for the installers to connect and configure to meet their requirements.

Summary of Invention

One problem with the existing products and soil pipe systems is that they are limited by the availability of the existing connectors and branches. In some building plumbing systems, the waste water pipes may be inconveniently located relative to the soil stack, and thus make connection to the soil stack difficult. For example, the building plumbing system may require the waste water pipes to be connected to the soil stack at angles for which preformed branches or connections are not available. In some situations, multiple pipes may need to be connected to the soil stack adjacent to each other and in a manner for which a preformed connector does not already exist or for which existing connectors would clash due to space requirements.

A further disadvantage of the existing products is that the construction of the soil stack is slow and laborious and subsequently requires testing which slows the installation further. To form the soil stack, a series of pre-formed connectors, branched pipe sections and pipes need to be sealed together. The components are either configured to slot together and seal with a flexible rubber gasket or ring seal, or alternatively, the components can be sealed together directly by plastics welding processes or by use of adhesives.

It is thus desirable to provide a pipe system and method of constructing a pipe system which resolves or ameliorates one or more of the existing problems or provides a useful alternative.

According to a first aspect of the invention, there is provided a branch connector for connecting to a pipe for forming a branched pipe. The branch connector may comprise a tube. The tube may have a seating portion at an end of the tube. The seating portion may comprise an arcuate surface. The arcuate surface may be for connecting to a pipe or cylinder.

Preferably, the seating portion may be configured to conform to the surface of a pipe or cylinder e.g. the arcuate surface may be curved so as to conform to the surface of the pipe or cylinder. In some embodiments, the pipe may not be cylindrical e.g. the pipe may have an elliptical cross-section. In some embodiments, the arcuate surface of the seating portion may be curved to conform to the surface of the alternative pipe cross- section. The arcuate surface may form and/or define a partial cylinder shape. The arcuate surface defines a partial cylinder shape when all points on the surface would lie on a cylindrical surface with the same radius as the arcuate surface.

The arcuate surface may form a complete cylinder shape and/or extends around less than 360 degrees. For example, the arcuate surface may form ¾ or ½ or ¼ of a cylinder shape or less and/or extends around 270, or 180 or 90 degrees or less.

The arcuate surface may have a radius configured so that the seating portion conforms to the surface of a soil pipe. The arcuate surface may have a radius configured so that the seating portion conforms to the surface of a soil pipe with a diameter of 56mm, 75mm, 82mm, 110mm, or 160mm.

The arcuate surface may have a central axis; the axis being defined by the centre of a fictional cylinder formed by extending the partial cylinder shape. The tube may have a tube axis, defined by the centre of the tube. The central axis and the tube axis may be orthogonal or oblique.

In one series of embodiments, the seating portion comprises a first arcuate surface and a second arcuate surface. The first and second arcuate surfaces may be configured to conform to the surface of pipes with different sizes, shapes and/or diameters. For example, the first and second arcuate surfaces may have different curve radiuses. The first arcuate surface may be configured to conform to a pipe with a first size and/or shape and the second arcuate surface may be configured to conform to a second pipe with a second, different size and/or shape. The first arcuate surface may be configured to have a greater curve radius than the second arcuate surface. In some embodiments, the first arcuate surface may be configured to fit to a pipe with a circular cross-section, and the second arcuate surface may be configured to fit to a pipe with a non-circular cross-section.

The first arcuate surface may extend around the exterior of the second arcuate surface. The second arcuate surface may extend or project from the first arcuate surface. Optionally, the seating portion may comprise a third or greater arcuate surface, wherein each arcuate surface has a different size, shape and/or curve radius. The tube may be linear. In some embodiments, the tube comprises a bend. The tube may have a cylindrical or elliptical cross section. The tube may have a teardrop shaped cross section. The tube may comprise a transitional region, wherein the cross sectional shape of the tube changes.

The seating portion may comprise a flange. The flange may extend around the circumference or perimeter of the tube. The flange may extend around the complete circumference or perimeter of the tube. The flange may comprise at least part of the arcuate surface. The flange may extend away from the tube. The flange may have a curved surface to conform to the shape of a pipe or cylinder. The flange may be rigid and configured to abut the pipe surface. The flange may be flexible or semi flexible.

The flange may comprise a heating wire e.g. for use in a plastics welding process, such as an electrofusion or induction welding process. The branch connector may further comprise at least one electrical connector for connecting the heating wire to a power source. In some embodiments, the heating wire may be configured to be heated by induction.

The branch connector may further comprise a pipe connector portion for connecting to a further pipe or tube. The pipe connector portion may be provided at an end of the tube opposite to the seating portion. The pipe connector portion may comprise any conventional fitting for connecting and sealing pipes together.

The branch connector may be formed from a plastics material. The branch connector may be formed from High Density Polyethylene (HDPE). Alternatively, the branch connector may be formed from PVC, polypropylene, polybutylene, ABS, low or medium density polyethylene, or other suitable plastics material.

According to a second aspect of the invention, there is provided a kit of parts comprising at least one branch connector according to the first aspect, and an elongate pipe.

The pipe may be a soil pipe. For example, the pipe may be a 110mm diameter soil pipe. The pipe may be a soil pipe with any other diameter such as 56mm, 75mm, 82mm or 160mm. The pipe may be formed from a plastics material. For example, the pipe may be formed from HDPE. Alternatively, the pipe may be formed from PVC-u, polypropylene, polybutylene, ABS, low or medium density polyethylene, or other suitable plastics materials. The kit may comprise multiple identical branch connectors, and/or comprise a variety of branch connectors of different sizes and/or angles and/or materials.

According to a third aspect of the invention, there is provided a method for constructing a branched pipe. The method may comprise providing an elongate pipe and at least one branch connector as described herein. The method may comprise determining an opening position in the wall of the pipe. The method may comprise locating the branch connector over the opening position. The method may comprise sealing the branch connector to the pipe around the opening position.

The method may further comprise forming an opening through the wall of the pipe in the opening position.

Forming the opening through the wall of the pipe may be carried out prior to locating the branch connector over the opening position and/or sealing the branch connector to the pipe around the opening position.

Forming the opening through the wall of the pipe may be carried out after locating the branch connector over the opening position and sealing the branch connector to the pipe around the opening position.

Forming an opening through the wall of the pipe may comprise cutting, laser cutting, milling, or drilling an opening extending through the thickness of the wall. Alternatively, other suitable techniques for forming the opening may be used.

The branched pipe may be a soil stack pipe. Optionally, the branched pipe may be a 110mm diameter soil pipe. Optionally, the branched pipe may have any other diameter as described previously. The elongate pipe may be formed from HDPE. The elongate pipe may be formed from an alternative material as described previously.

The seating portion may comprise a flange. The flange may extend around the circumference and/or outer perimeter of the opening position. The flange may be configured to abut the surface of the pipe around the circumference and/or perimeter of opening.

Sealing the branch connector to the pipe around the opening position may comprise making a fluid-tight seal. Sealing the branch connector to the pipe may comprise any one or more of plastics welding, adhesion with an adhesive, or one or more mechanical fasteners. Plastics welding may comprise any one or more of butt welding, electrofusion welding, solvent welding, ultrasonic welding, induction welding, friction welding, laser welding, IR welding or Radio Frequency (RF) welding. Butt welding and electrofusion are particularly advantageous, since they are reliable and inexpensive processes.

Sealing the branch connector to the pipe may comprise providing one or more heating wires on the branch connector. Sealing the branch connector to the pipe may comprise locating the branch connector over the opening position and heating the one or more heating wires on the branch connector to heat the branch connector and pipe and form a bond. The heating wires may be connected to a power source, for example by a wire or cable. Alternatively, the heating wires may be heated inductively.

The opening in the pipe may have a circular, oval, or tear-drop shaped cross-section in an axis perpendicular or oblique to the axis of the elongate pipe.

The method may further comprise providing a second branch connector as described herein. The method may further comprise determining a second opening position in the wall of the pipe. The method may further comprise locating the second branch connector over the second opening position. The method may further comprise sealing the second branch connector to the pipe around the second opening position.

The method may further comprise third, or fourth, or greater number of branch connectors and opening positions.

The method may comprise forming a first branch and at least a second branch substantially simultaneously. The method may comprise sealing a first and second branch connector to the pipe substantially simultaneously. The method may comprise forming a first opening and a second opening substantially simultaneously. In some embodiments, the method may comprise sealing a first branch connector to the pipe and forming a second opening simultaneously, and/or sealing a second branch connector to the pipe and forming a first opening simultaneously.

The method may comprise sealing at least a first and second branch connector to the pipe at a first and second opening position, wherein the first and second opening positions are spaced apart in the axial length of the pipe.

The method may comprise sealing a first and second branch connector to the pipe at a first and second opening position, wherein the first and second opening positions are spaced apart in a circumferential direction of the pipe.

According to a fourth aspect of the invention, there is provided a branched pipe formed by the method described herein. The branched pipe may comprise at least 1 branch. In some embodiments, the branched pipe may comprise at least 5 branches, or at least 10 branches.

Brief Description of the Figures

Embodiments of the invention will now be described with reference to the following figures in which:

Figures 1A-D are top, isometric, side and end views of a first embodiment of branch connector;

Figures 2A-D are top, isometric, side and end views of a second embodiment of branch connector;

Figures 3A-D are top, isometric, side and end views of a third embodiment of branch connector;

Figures 4A-D are top, isometric, side and end views of a fourth embodiment of branch connector;

Figure 5 is a perspective view of a fifth embodiment of branch connector;

Figures 6A-B are end and isometric views of a sixth embodiment of branch connector;

Figures 7A-D are top, isometric, side and end views of a seventh embodiment of branch connector; Figure 8 is a top view of an eighth embodiment of branch connector;

Figures 9A-C are side, perspective and top views of a ninth embodiment of branch connector; and

Figures 10A-B are side and perspective views of a branched pipe.

Specific Description

Turning now to Figures 1A-D, there is shown a first embodiment of a branch connector 100 from a variety of angles. Figure 1A is a top view; Figure 1B is an isometric view; Figure 1C is a side view: and Figure 1D is an end view. The dashed lines represent internal contours or surfaces, with the dotted and dashed line 101 representing a central axis through the branch connector 100.

The branch connector 100 has a tube 102, in this embodiment with a circular cross- section as shown in the end view Figure 1D. The tube 102 has a seating portion 104 at a first end of the tube 102. The seating portion 104 has an arcuate surface 106 for positioning against the surface of a pipe (not shown) for forming a branched pipe. The seating portion 104 extends around the full circumference of the tube 102, thus forming a curved ring shape. As shown in Figures 1A and 1C, the seating portion 104 is recessed in a central region 105a when viewed from above and extends further from the tube 102 in the lateral regions 105b to conform to the surface of a pipe or cylinder. Thus, the arcuate surface defines a partial cylinder shape, since the arcuate surface itself lies on a hypothetical cylindrical surface. A partial cylinder shape is defined, since the arcuate surface extends through a limited arc and less than 180°.

The second end of the tube 102 opposite the seating portion 104 is left with a flat edge 107 for connecting to a further pipe in a conventional manner (for example via a socket or fusion coupling). A further pipe can be joined directly onto the flat edge 107 (e.g. via butt welding or similar process), or alternatively the further pipe can be located over the tube 102, so that the tube 102 is received within the further pipe.

The branch connector 100 forms a right angled branch with the pipe to which it is to be fitted. When the branch connector 100 is in situ on a pipe, the axis 101 would be orthogonal to the longitudinal axis of the pipe. Turning now to Figure 2A to 2D there is shown a second embodiment of a branch connector 200 from a variety of angles. Figure 2A is a top view; Figure 2B is an isometric view; Figure 2C is a side view: and Figure 2D is an end view. The branch connector 200 is similar to the branch connector 100, and the numbering herein is intended to reflect identical or equivalent features.

The branch connector 200 has a tube 202, in this embodiment with a circular cross- section as shown in the end view Figure 2D. The tube 202 has a seating portion 204 at a first end of the tube 202. The seating portion 204 has an arcuate surface 206 for positioning against the surface of a pipe (not shown) for forming a branched pipe.

The seating portion 204 extends around the full circumference of the tube 202, thus forming a curved ring shape. The tube 202 has a greater diameter than the tube 102, and thus the arcuate surface 206 extends through a greater arc. The arcuate surface 206 extends through an arc of less than 180° so that two branch connectors 200 can be positioned on opposite sides of a pipe. For example, the arcuate surface 206 has an arc of approximately 160°. As shown in Figures 2A and 2C, the seating portion 204 is recessed in a central region 205a when viewed from above and extends further from the tube 202 in the lateral regions 205b to conform to the surface of a pipe or cylinder.

The second end of the tube 202 opposite the seating portion 204 is provided with a pipe connector portion 209 comprising a threaded region 211. The threaded region 211 is configured to receive a cap (not shown) or a further pipe with a correspondingly threaded connector.

In Figures 3A to 3D, there is shown a third embodiment of branch connector 300. The branch connector 300 is similar to the branch connectors 100, 200, and like parts will not be described further.

The branch connector 300 has a tube 302 which is curved. As shown in Figure 3C, when viewed from the side, the tube 302 curves downwards, although it would be understood that the direction depends on the orientation of the pipe to which the branch connector 300 is to be fitted. Such a downward curve may be selected to improve fluid flow through the branch connector 300 for example. The tube 302 has a pipe connector portion 309 which is a section of straight cylindrical pipe, although it will be appreciated that any other suitable pipe connector portion could be used, such as that shown in Figures 2A-2D.

The seating portion 304 of the branch connector 300 does not have a circular cross- section, as best shown in Figure 3D. The seating portion 304 forms a complete loop around the tube 302. However, due to the bend of the tube 302, the seating portion 304 is elongated in the direction of the bend i.e. downwards.

In further embodiments (not shown) the direction of the bend may be different. For example, the bend may curve sideways (relative to the elongate axis of the pipe to which it is to be joined), so that the pipe connector portion 309 is offset from the centre of the pipe to which the branch connector 300 is to be fitted. In such an embodiment, the seating portion 304 would be elongated laterally or horizontally. In some embodiments, the tube 302 may have a bend in an oblique direction relative to the axis of the pipe to which it is to be connected.

Turning now to Figures 4A to 4D there is shown a further embodiment of the branch connector 400.

The branch connector 400 comprises a tube 402 and a seating portion 404 as described previously. The seating portion 404 has a broad flange 412 which extends away from the tube 402. As pictured best in Figures 4A and 4D, the flange 412 provides a large surface area which extends a much greater distance from the tube 402 than the comparable seating portions 104, 203, 304 of the previous embodiments.

The branch connector 400 is further provided with a pair of electrical connectors 414. The electrical connectors 414 are ports or sockets for receiving wires or cables for powering a heating coil provided on the flange (not shown).

Turning now to Figure 5, there is shown a branch connector 500, which is similar to the branch connector 200 as shown in Figures 2A to 2D. The branch connector 500 is also provided with a flange 512 and electrical connectors 514 as described with reference to Figures 4A-D. Figures 6A and 6B show a branch connector 600 which is similar to the branch connector 300 as shown in Figures 3A-D. The branch connector 600 has a swept or bent tube 602 and is surrounded by a seating portion which comprises a flange 612. The flange is provided with a pair of electrical connectors 614 as described previously.

As with the branch connectors 400, 500, the branch connector 600 has a wire coil 616 on the inner surface thereof. The inner surface is the surface of the flange 612 which would directly contact the pipe or cylinder to which the branch connector is to be joined. The wire coil 616 is connected to the electrical connectors 614. The wire coil 616 is a heating coil, and thus on passing a current through the wire coil 616, the material of the flange 612, and/or of the pipe or cylinder to which the branch connector 600 is to be joined, is heated to a temperature to permit welding i.e. an electrofusion welding process. In alternative embodiments, multiple wire coils may be provided or a series of wire elements arranged in parallel can be used.

It will be understood that the branch connectors can be provided in a wide range of sizes and configurations, and with or without wire coils without departing from the scope of the invention.

Turning now to Figures 7A-7D, there is shown a branch connector 700. The branch connector 700 differs from the previously described branch connectors in that the central axis of the branch connector is configured to be angled relative to the central axis 703 of the pipe to which the branch connector 700 is to be fitted. When the branch connector 700 is in situ on a pipe, the axis 701 would be at an oblique angle to the longitudinal axis 703 of the pipe.

Turning now to Figures 8 and 9A-C, there are shown two further embodiments of branch connector. The branch connector 800 is similar to the branch connector 100, and parts in common will not be re-described. The branch connector 900 is a bend connector, wherein the tube 902 has a bend of approximately 45°.

The branch connector 800 has a tube 802 and a seating portion 804. The seating portion 804 differs from the previously described embodiments since it is provided with a first arcuate surface 806a and a second arcuate surface 806b. The first and second arcuate surfaces 806a, 806b have different curve radiuses. The curve radius of the first arcuate surface 806a is greater than the curve radius of the second arcuate surface 806b. Similarly, the seating portion 904 of the branch connector 900 has first and second arcuate surfaces 906a, 906b.

The second arcuate surface 806b, 906b extends from the first arcuate surface 806a, 906b. The first arcuate surface thus extends around the outside of the second arcuate surface. Thus, in order to connect the branch connector to a pipe by the first arcuate surface, a larger hole is cut into the wall of the pipe. Thus when connected the second arcuate surface will extend a short distance into the pipe. The second arcuate surface can be configured to extend from the first arcuate surface by approximately the thickness of the pipe walls, and thus once connected, the interior of the pipe is not obstructed.

The first and second arcuate surfaces 806a, 806b, 906a, 906b are configured to contact and seal against pipes of different radiuses. Since pipes are available in a wide range of sizes (i.e. diameters) the arcuate surface needs to have a corresponding curve radius in order to contact the outer surface of the pipe and be effectively sealed thereto. Thus, in embodiments with first and second arcuate surfaces, a single branch connector can be used with, and connected to, two different sizes of pipe. Preferably the radiuses are selected to correspond to the two most common pipe diameters for each particular application. For example, the curve radiuses of the first and second arcuate surfaces may be configured so that they can be sealed against common soil pipe sizes, such as 110mm and 82mm, or 110mm and 160mm. Thus the total number of unique components can be reduced.

In further embodiments (not shown) a third or greater arcuate surface can be provided in order to allow the branch connector to connect to multiple different sizes of pipe.

Turning now to Figures 10A and 10B, further aspects of the invention will be described. Figures 10A and B are side and perspective views respectively of a branched pipe 10. Branched pipe 10 is a prefabricated soil stack pipe - a main pipe connection to a sewer pipe network. The soil stack is typically provided on the interior of a building (although they may be external), and receives waste water from multiple building pipes. The branched pipe 10 is thus highly configurable in order to connect a building’s multiple waste pipes to an underground sewer pipe. The branched pipe 10 is predominantly formed from a pipe 11, and provided with a connector 12 at its upper end for connecting to a further pipe 11 to extend the overall length of the branched pipe 10. In some embodiments the connector 12 may be replaced with a vent cowl (e.g. for terminating the stack above the roof level) or it may be connected to an alternative vent arrangement. The connector 12 may be integrally formed with the pipe 11, or it may be connected thereto by any process described previously (such as plastics welding, adhesives or mechanical means). Preferably, the connector 12 is friction welded to an end of the pipe 11.

Spaced along the length of the pipe 11 are a series of branch connectors 100, 200, 300. In alternative embodiments (not shown) branch connectors 400, 500, 600 are used instead of or in addition to the branch connectors 100, 200, 300.

Each branch connector is provided for connecting to a waste pipe within a building’s waste water plumbing. In the circle A there is shown a pair of branch connectors 100 arranged at 90° to each other. In the circle B there is shown a branch connector 100 and a branch connector 300 immediately above. The embodiment shown demonstrates that it is possible to arrange multiple branch connectors on the pipe 11 with much greater configurability. In the branched pipe 10, it is possible to provide branch connectors much closer to each other than previously known. A further advantage is that fewer distinct components are required.

The branched pipe 10 is formed by first providing the elongate pipe 11. A series of opening positions is determined along its length, each opening position corresponding to one of the branch connectors 100, 200, 300. The size, shape and position of the opening positions depend on the specific requirements of the building plumbing and the number of pipes which need to be connected. The branch connectors 100, 200, 300 are then located over their respective opening positions. The branch connectors are then sealed to the pipe 11.

An opening is formed in the pipe 11 at the opening position either before or after locating and sealing the branch connector to the pipe. Where the opening is formed prior to locating and sealing the branch connector, the opening may assist in aligning the branch connector, and may utilise a jig or former. Alternatively, the opening may be formed after the branch connector is sealed to the pipe - for example by a tool inserted through the tube and seating portion of the branch connectors. In some embodiments, the opening may be formed using a tool located inside the pipe 11. Forming the opening can be achieved by any suitable technique, such as drilling, milling, cutting or laser cutting for example.

The branch connectors are sealed to the pipe by any suitable method. Typically, this comprises sealing the seating portion and/or the flange to the pipe. Since each branch connector is provided with a curved/arcuate seating portion configured to conform to the outer pipe surface, a reliably connection and seal is reliably attainable. For example, this may comprise plastics welding, such as any welding process described previously, including butt, solvent, or sonic welding, or adhesives may be used. For butt welding, the branch connectors and the pipe may be heated by a heating surface before pressing the two parts together to form a fluid tight seal. Alternatively, the branch connectors and pipe may be heated radiatively, such as by an I R heater, by a laser or by high frequency radio waves. A further alternative may be the use of electrofusion or induction welding, by using branch connectors as described previously with integrated heating coils. The branch connectors can be positioned on the pipe and the coils heated by an electrical current or an electromagnetic field to heat both the branch connector and the adjacent region of pipe. Preferably, for plastics welding processes, both the branch connector and pipe are formed from a plastics material, and more preferably, the same plastics material.

In alternative embodiments (not shown) the pipe and branch connector may be formed from metal, and they may be sealed together by welding, soldering, brazing or other suitable method.

The method utilises branch connectors which connect directly to the pipe surface and thus the final branched pipe can be adapted more specifically for a particular installation. For example, it is only necessary to provide a branch connector where a pipe from the building’s plumbing would connect to the pipe 11. For example, in the region A of Figure 9B, two branch connectors are provided at 90° to one another. In a conventional system, it is necessary to use a moulded pipe section provided with branch connectors. To reduce the number of parts, it may be necessary to use a pipe section with four branch connectors, and cap off the two unused connectors. The pipe section is then joined to the rest of the pipe at each end to form a continuous soil stack. Although such an approach is often effective, it is wasteful, and moulding the four-way connector is expensive. Furthermore, although region A shows two connectors at 90° to each other, in the present invention, almost any angle is possible.

As shown in region B, it is also possible to locate different branch connectors much closer to each other, and thus optimise the branched pipe 10 for a specific plumbing system. In a conventional system, it would either be impossible to locate two connectors so close together, or require a pipe section be manually fabricated which is slow and laborious, and generates a significant amount of waste due to the excess parts of off-the-shelf connectors being discarded afterwards. Such parts are thus significantly more expensive. In conventional systems, the installers are restricted by the existence of pre-moulded pipe sections with the necessary branch connectors pre formed. Thus the range of options to the installers are significantly limited compared to the present invention.

An advantage of the manufacture method is that it may be automated in a factory by a machine which forms the openings and locates and seals the branch connectors to the pipe. By automating the process, it is possible to locate and seal multiple branch connectors to the pipe simultaneously. Thus, the branched pipes can be formed more quickly than current methods, while still being more adaptable. The branched pipes or soil stacks can be made in advance and simply installed on site with little or no modification on site. The final branched pipe or soil stack can be consistently formed with a reduced failure rate and tested off site, while the plumbing installation time on site is greatly reduced.

Additionally, the present invention benefits by being able to use long extruded sections of pipe 11, which are readily available, as the main component. In existing methods, a series of moulded pipe sections are provided with pre-moulded branch connectors and the pipe sections are connected by short lengths of straight pipe. This requires a greater number of different pipe sections which increases manufacturing cost and reduces adaptability.

In some embodiments, it may be desirable to provide the branch connectors, and optionally the pipe, as a kit of parts for installation on site. In such embodiments, the number of unique parts, as well as the number of surplus parts, is reduced. This can eliminate or reduce the need for individual packaging of the parts and thus reduces waste of cardboard and other packaging materials. Furthermore, providing the branched pipe as a kit of parts allows for retrofitting of additional branch connectors as needed as the plumbing requirements change over the building’s lifetime.