Check Valve Sheet-Metal Flap Module Design
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Solution Overview
Problem
Existing check valves with levers are complex and costly to manufacture, requiring precise alignment and additional components like castings and screw locking devices, which increase weight and mounting complexity, and often obstruct fluid flow.
Innovation Solution
A check valve design featuring a flap module with sheet-metal shaped parts, including a lever and bearing device, which simplifies assembly and reduces weight by eliminating the need for re-machining and additional components, using a detent connection and a separate insert for the bearing device that is easy to manufacture and mount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cast levers are used with screw connections, then the structural strength is improved, but the manufacturing complexity and mounting outlay increase
Solution Approach 1:
The lever and shut-off body are merged into a single integral component, eliminating the need for separate screw connections and locking devices. This integration maintains structural strength while significantly reducing assembly complexity and mounting outlay.
Solution Approach 2:
The integral lever-shut-off body design serves multiple functions simultaneously: it provides the lever arm for operation, forms the shut-off body that seals against the seat, and eliminates the need for separate connection and locking mechanisms, thereby reducing overall device complexity.
2Quantity of substance
If cast levers with minimum wall thickness are used, then the material usage is reduced, but the centre of gravity shifts towards the axis of rotation requiring additional compensating weights
Solution Approach 1:
The lever is designed with an asymmetric thin-walled structure where the wall thickness varies strategically. The lever arm portion can have reduced thickness while the connection to the shut-off body maintains sufficient thickness, creating an optimized center of gravity position without requiring compensating weights.
3Manufacturing precision
If precise alignment and re-machining are required, then the manufacturing precision is improved, but the manufacturing costs and time increase
Solution Approach 1:
The lever and shut-off body are manufactured as a pre-assembled integral component with built-in alignment features. This preliminary integration eliminates the need for subsequent re-machining and alignment operations, reducing both manufacturing time and costs while maintaining precision.
4Reliability
If additional screw locking devices are introduced, then the reliability of the connection is improved, but the device complexity and mounting outlay increase
Solution Approach 1:
The connection between the lever and shut-off body is achieved through integral formation rather than separate fastening components. This merging eliminates the need for screw locking devices while maintaining connection reliability through the monolithic structure.
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 design reduces manufacturing costs and complexity, allows for easier assembly, and minimizes the impact on fluid flow by eliminating the need for precise alignment and additional components, while maintaining effective sealing and fluid direction control.
Implementation Method 1
the overall effect of the torques produced as a result of the inertial forces of the flap module (lever, flap, add-on pieces) is that the flap in every intended installation position of the valve is pressed against the seat face or valve seat and the valve is closed
Data Source
AI summary
The invention relates to a check valve for blocking a fluid-carrying line in case of reversal of the flow direction, containing a valve housing defining a flow path and having two connecting pieces and a valve seat therebetween, and a flap module mounted in the valve housing and containing a shut-off body interacting with the valve seat, a bearing device for pivotably supporting the shut-off body such that the latter is movable between an open position and a closed position, and a lever extending between the shut-off body and the bearing device and being connected to the shut-off body and the bearing device. For easier manufacturing, the invention proposes that a part of the flap module is formed by at least one sheet-metal shaped part.