Castellated Check Valve Geometry to Prevent Sticking in Assembly
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Solution Overview
Problem
Conventional check valves with disc-shaped valve members made of silicone suffer from sticking issues during bulk packing and assembly due to their flat geometry, leading to 'shingling' and difficulties in automated assembly.
Innovation Solution
The design incorporates a valve member with a 'jack' shape geometry featuring a valve stem portion and castellated feet, reducing exposed surface area for sticking and preventing contact between valve surfaces, thereby minimizing friction and sticking during assembly and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disc-shaped valve members with flat geometry are used, then the valve structure is simple and easy to manufacture, but the valve members stick together during bulk packing and assembly due to increased exposed surface area
Solution Approach 1:
The valve member is segmented from a flat disc into a three-dimensional structure with a central valve stem portion and multiple radially extending feet. This segmentation creates gaps between adjacent feet, preventing the valve members from sticking together during bulk packing and assembly while maintaining manufacturing feasibility through injection molding processes.
2Ease of manufacture
If flat disc-shaped valve members are used, then manufacturing is easier, but automated assembly becomes difficult due to shingling
Solution Approach 1:
The valve member transitions from a two-dimensional flat disc to a three-dimensional structure with vertical height created by the valve stem and feet. This dimensional change eliminates the shingling problem that plagues automated assembly of flat discs, allowing valve members to be easily fed and positioned by automated equipment without sticking together.
3Adaptability or versatility
If silicone material is used for valve members, then the material is flexible and suitable for check valve function, but the natural stickiness causes sticking issues
Solution Approach 1:
By segmenting the silicone valve member into a multi-foot structure with a central stem, the design reduces the total exposed surface area that can stick to other valve members. The gaps between feet prevent continuous contact surfaces, thereby mitigating the natural stickiness of silicone material while preserving its flexibility for proper check valve operation.
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
The solution reduces the exposed surface area for sticking by up to 69%, facilitating easier assembly and transportation by keeping valve surfaces apart, and allows for concentric alignment within the check valve cavity even under back pressure.
Implementation Method 1
permit fluid flow in a first direction, and prevent fluid backflow in a second direction opposite to the first direction
Implementation Method 2
The valve member is formed of an elastomeric material
Data Source
AI summary
A check valve includes an upper housing defining an inlet of the check valve, a lower housing defining an outlet of the check valve, and a cavity interposed between and defined by the upper and lower housings for fluidly connecting the inlet and the outlet. The check valve further includes a valve member mounted in the cavity to selectively permit fluid flow in a first direction, and prevent fluid backflow in a second direction opposite to the first direction. The valve member includes a valve body and a valve stem portion extending axially through a central axis of the valve body. The valve member may further include a plurality of feet disposed about and extending longitudinally from an outer circumferential perimeter of the valve body.