Ball Valve Cartridge for Freezeless Hydrants

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Solution Overview

Problem

Ceramic disk valve elements in freezeless hydrants are prone to failure due to spring failure, material expansion issues, water retention, sediment blockage, and higher costs, limiting flow rate and reliability in extreme temperatures.

Innovation Solution

A compact ball valve cartridge with an internal stem and rotational stop elements, allowing quarter-turn operation, is developed to increase freeze resistance and ease of production, using materials like brass, stainless steel, or PVC, and incorporating a drain valve for yard hydrant applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If ceramic disk valve elements are used in freezeless hydrants, then the valve can operate in extreme temperatures, but the reliability decreases due to spring failure, material expansion issues, and water retention

Engineering Contradiction:

Improveextreme temperature resistanceVSAvoidvalve reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent replaces the expensive and unreliable ceramic disk with a simpler, more reliable ball valve mechanism that can be easily replaced. The ball valve is designed as a cartridge assembly that can be quickly swapped out, making the system more reliable overall despite using less expensive components.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the fundamental operating parameter from ceramic disk rotation to ball valve quarter-turn operation. This parameter change eliminates the spring compression and ceramic expansion issues while maintaining extreme temperature resistance through the use of a simple ball and seat design.

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If ceramic disk valve elements are used, then the valve can provide flow control, but the flow rate is limited compared to ball valve elements

Engineering Contradiction:

Improveflow rateVSAvoidmanufacturing complexity

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent uses a standard ball valve element instead of a custom ceramic disk, which increases flow rate and is easier to manufacture. The ball valve is a common, readily available component that can be produced more easily than precision-crafted ceramic disks.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If ceramic disk valve elements are used, then the valve can provide flow control, but sediment blockage becomes more likely

Engineering Contradiction:

Improveflow control capabilityVSAvoidsediment blockage

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent uses a spherical ball valve element instead of a flat or contoured ceramic disk. The spherical shape has no corners or crevices where sediment can accumulate, making it resistant to blockage while maintaining effective flow control through the ball's hole alignment.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Manufacturing precision

If ceramic parts are used in the valve, then the valve can provide precise flow control, but the machining difficulty and cost increase

Engineering Contradiction:

Improveflow control precisionVSAvoidmachining difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces difficult-to-machine ceramic parts with a standard ball valve assembly that is readily available and easy to install. The cartridge design allows the entire valve assembly to be replaced as a unit, eliminating the need for precision machining of individual components.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

5Productivity

If the ball valve is positioned closer to the actuator, then the operation is more efficient, but the freeze resistance decreases

Engineering Contradiction:

Improveoperation efficiencyVSAvoidfreeze resistance

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent uses a quarter-turn ball valve mechanism that rotates 90 degrees to open or close flow. This dimensional change in operation (from multi-turn to quarter-turn) allows the valve to be positioned optimally for freeze resistance while maintaining efficient operation through the simple quarter-turn action.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS7975720B2Ball valve cartridge for use with remote handle

Publication Date: 2011.07.12 TOP SHELF MFG

AI summary

A ball valve cartridge is disclosed. It is especially well suited for freezeless hydrant applications and any other application where it is positioned remotely from a handle or other actuating element. The cartridge contains a ball valve element and an internal stem with a key for rotating the ball valve element between open and closed positions. The stem has rotational stop elements that limit rotational movement of the stem and the ball valve element. In a yard hydrant application, a drain valve can be added to regulate the opening and closing of the drain hole. It has an operational range of a quarter turn or ninety degrees.