Insert-Molded Composite Valve Structure Against Distortion
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Solution Overview
Problem
Conventional valves face challenges in preventing distortion when combined with pipes or other valves, as they either lack strength due to being made of plastic or are expensive and difficult to process when made of metal.
Innovation Solution
A valve design incorporating a metal member within a plastic main body, where the metal member is surrounded by sub-metal members and embedded through insert molding, ensuring strength and preventing distortion while maintaining ease of processing and low manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the valve is made of metal, then strength is improved, but manufacturing cost increases and processing difficulty increases
Solution Approach 1:
The valve combines metal and plastic materials to create a composite structure where the metal member provides strength and the plastic main body provides ease of manufacturing. This composite approach allows the valve to achieve both high strength and easy manufacturing processes.
Solution Approach 2:
The valve is divided into separate metal and plastic components that are manufactured independently and then combined through insert molding. The metal member is manufactured separately with embedded holes, while the plastic main body is molded around it, allowing each component to be optimized for its specific material properties.
2Ease of manufacture
If the valve is made of plastic, then manufacturing cost is reduced, but distortion occurs when combined with pipes or valves
Solution Approach 1:
The valve combines metal and plastic materials to create a composite structure where the metal member provides strength and distortion resistance while the plastic main body provides ease of manufacturing. This composite approach allows the valve to achieve both high strength and easy manufacturing processes.
Solution Approach 2:
The metal member is strategically positioned within the plastic main body at locations requiring high strength and distortion resistance. The insert molding process embeds the metal member with pre-formed holes into the plastic, creating localized reinforcement where needed while maintaining overall plastic construction benefits.
3Stability of the object's composition
If metal member is embedded in plastic main body, then distortion is prevented, but manufacturing complexity increases
Solution Approach 1:
The metal member is prepared in advance with the required holes formed before the insert molding process. This preliminary preparation of the metal member allows for precise hole placement and dimensions to be achieved through standard metalworking processes, and then the pre-prepared metal member is simply embedded into the plastic main body during molding.
Solution Approach 2:
The insert molding process combines the metal member embedding and plastic main body formation into a single integrated manufacturing step. The metal member is placed in the mold cavity, and plastic is injected around it in one continuous process, eliminating the need for separate assembly operations and reducing overall manufacturing complexity.
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 effectively prevents distortion and enhances the strength of the valve when combined with pipes or other valves, while reducing manufacturing costs and processing complexities compared to traditional metal or plastic valves.
Implementation Method 1
at least one hole in which melt plastic is filled when an insert molding is performed is formed on the metal member, and the metal member is included in the main body through the insert molding
Data Source
AI summary
Various valves capable of preventing distortion are disclosed. The valve comprises a metal member configured to have at least two sub metal members and a main body. Here, the sub metal members are included in the main body, and the main body is formed of plastic.