Ball Valve End Cap Assembly Using a Plastically Deformed Lip
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Solution Overview
Problem
Traditional ball valve manufacturing methods require skilled labor to ensure correct torque and pressure for end cap attachment, leading to potential over-tightening or leakage issues, increased production time, and costs due to threading requirements and additional material needed for tool purchase points.
Innovation Solution
The use of a plasticly deformed lip to attach the end cap to the valve body allows for automation of the fitting process, reducing the need for threads and skilled labor, while ensuring consistent pressure and seal integrity, thus lowering manufacturing costs and enabling smaller valve designs for tighter spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded connections are used to attach end caps to the valve body, then the connection strength is improved, but the manufacturing complexity and labor skill requirements increase
Solution Approach 1:
The patent removes the threading feature from the valve body and end caps, extracting the complex threaded connection mechanism and replacing it with a simple push-fit arrangement where the end cap is inserted into the valve body without threads, thereby reducing manufacturing complexity while maintaining connection strength through the interference fit and retaining ring mechanism
Solution Approach 2:
The patent replaces the mechanical threading system with a deformation-based mechanical system where a retaining ring is deformed radially inward to engage with grooves in the valve body, creating a secure connection without requiring threaded holes or threads on the main components
2Reliability
If threaded connections with manual calibration are used, then the seal integrity can be controlled, but the production time and labor costs increase
Solution Approach 1:
The patent implements a self-calibrating mechanism where the end cap, when pushed into the valve body, automatically deforms the retaining ring radially inward to engage with the grooves, and the spring-loaded design ensures automatic sealing pressure is applied to the ball valve seat, eliminating the need for manual torque calibration and enabling automated assembly
Solution Approach 2:
The retaining ring is pre-formed with radial flexibility and the end cap is designed with features that automatically position and compress the retaining ring during insertion, so that the sealing action is prepared and executed automatically as part of the assembly process rather than requiring separate calibration steps
3Strength
If threads are machined on the valve body and end caps, then the attachment strength is improved, but the manufacturing time and costs increase
Solution Approach 1:
The patent removes the threading operation from the manufacturing process by eliminating threads from the valve body and end caps, replacing them with simple cylindrical surfaces that require no machining beyond basic turning, thereby significantly reducing manufacturing time and costs while maintaining attachment strength through the interference fit and retaining ring engagement
Solution Approach 2:
The patent changes the geometric parameters of the connection interface by using an interference fit design where the end cap outer diameter is slightly larger than the valve body inner diameter, creating a press-fit connection that eliminates the need for threading operations and reduces manufacturing complexity
4Ease of operation
If additional material is added for tool purchase points, then the ease of assembly is improved, but the valve dimensions increase
Solution Approach 1:
The patent implements self-aligning features where the end cap and valve body have built-in positioning elements such as grooves and protrusions that automatically guide the assembly process, eliminating the need for external tool purchase points and keeping the valve compact without sacrificing ease of assembly
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach streamlines the manufacturing process, reduces labor and material costs, and ensures consistent, watertight seals without the need for manual calibration, making the production of ball valves more efficient and aesthetically pleasing.
Implementation Method 1
the valve body comprises a plasticly deformed lip; wherein the plasticly deformed lip is configured such that it at least partially envelops the connecting portion, thereby attaching the end cap to the valve body
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A valve 1 and method of valve assembly are provided. The valve 1 having at least a valve member 3, a valve body 2 and an end cap 4. The valve body 2 or the end cap 4 has a connecting portion 9 and the corresponding other of the valve body 2 or the end cap 4 has a plasticly deformed lip 8. The plasticly deformed lip 8 at least partially envelops the connecting portion 9, thereby attaching the end cap 4 to the valve body 2.