Composite Plastic Butterfly Valve Disc for Pressure and Corrosion
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Solution Overview
Problem
Butterfly valves in pipeline construction face issues with high weight and corrosion when metal components are used, and the detachment of plastic layers leads to failure in withstanding internal pressures and maintaining corrosion resistance.
Innovation Solution
A butterfly valve design featuring a core and shell made of different plastics, where the core is high-strength and reinforced, and the shell is medium-resistant, assembled using a plug-in shaft for simple assembly and corrosion protection, with no material bond between the core and shell, ensuring the valve can withstand internal pressures and resist corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal plates are used to attain high strength, then the valve can withstand internal pressures, but the weight increases and corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining plastic core with fiber reinforcement (such as glass fibers or carbon fibers) to create a disc that achieves high strength comparable to metal while maintaining the lightweight advantage of plastic materials. The composite structure allows the valve disc to withstand internal pipeline pressures without the weight penalty of solid metal construction.
Solution Approach 2:
The patent implements local quality by reinforcing specific areas of the disc with fibers or other strengthening elements rather than using solid metal throughout. The core remains plastic for lightweight properties, while localized reinforcement provides the necessary strength in critical areas to handle internal pressures, optimizing the weight-strength balance.
2Object-affected harmful factors
If metal valves are coated with corrosion-resistant layer, then corrosion protection is improved, but the complexity increases and reliability deteriorates when coating detaches
Solution Approach 1:
The patent extracts the corrosion problem entirely by removing metal from the valve disc construction and using plastic composite materials instead. This eliminates the need for corrosion-resistant coatings and their associated reliability issues with coating detachment. The plastic material inherently resists corrosion while maintaining structural integrity.
Solution Approach 2:
The patent uses plastic materials that inherently resist corrosion without requiring additional protective layers. While plastic may have different lifespan characteristics compared to metal, it eliminates the coating system entirely, reducing complexity and avoiding the failure mode of coating detachment that plagues coated metal valves.
3Ease of manufacture
If disc is made as single piece, then manufacturing simplicity is improved, but the ability to combine different material properties deteriorates
Solution Approach 1:
The patent segments the disc into a core structure and reinforcement elements (such as fiber layers or injected material). This segmentation allows different materials with complementary properties to be combined - the plastic core provides baseline strength and corrosion resistance, while the reinforcement layers add tensile strength and structural rigidity. The segmented approach enables optimization of each component's material properties.
Solution Approach 2:
The patent creates a composite structure by combining plastic core material with fiber reinforcement (glass fibers, carbon fibers, or other suitable reinforcements). This composite construction allows the valve disc to achieve superior mechanical properties that neither material could provide alone, while still being manufacturable through established composite processing techniques.
4Strength
If shaft is permanently fixed in disc, then connection strength is improved, but assembly simplicity deteriorates
Solution Approach 1:
The patent applies preliminary action by creating a prepared receptacle or mounting structure in the disc during the molding process. This pre-prepared feature allows the shaft to be easily inserted and secured without complex assembly operations. The receptacle may include features such as interference fits, snap-in mechanisms, or adhesive bonding surfaces that are already formed in the disc, enabling simple yet strong shaft attachment.
Data Source
AI summary
Butterfly valve for shutting off or regulating a medium, which flows through a pipeline, containing a housing, wherein the housing is configured in one piece and is preferably composed of plastic, a disc and a shaft, wherein the disc can be pivoted along the shaft between an open position and a closed position, wherein the disc comprises a core composed of plastic and a shell composed of plastic, wherein the plastic of the core and the plastic of the shell are different.