Control Valve Valve Body Molding for Sealing and Sliding Surfaces
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Solution Overview
Problem
Existing control valves face challenges in maintaining sealing and sliding properties due to resin molding processes, leading to potential deformation and reduced performance, particularly when the core layer is exposed on critical surfaces.
Innovation Solution
The control valve design incorporates a core exposed portion on the connection surface of the valve body, which is not present on the seat surfaces or sliding surfaces, and utilizes a specific molding process where the gate portion is cut to minimize exposure on these critical areas, thereby reducing the risk of deformation and enhancing sealing and sliding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the valve body is molded using a gate in the resin molding process, then the manufacturing is simplified and productivity is improved, but the gate trace remaining on the valve body surface causes deterioration of sealing and sliding properties
Solution Approach 1:
The invention extracts and removes the harmful gate trace from the critical functional surfaces (seat surfaces and sliding surfaces) through post-molding cutting processes. The gate trace is completely removed from surfaces that require high sealing and sliding properties, while preserving the benefits of gate-based molding for productivity.
Solution Approach 2:
The invention applies different surface qualities to different regions of the valve body. Critical surfaces (seat and sliding surfaces) have the gate trace removed to maintain high sealing and sliding properties, while non-critical surfaces retain the gate trace structure. This local differentiation optimizes both manufacturing efficiency and functional performance.
2Reliability
If the gate portion is completely removed from the molded body, then the sealing and sliding properties are improved, but the number of manufacturing steps increases and productivity decreases
Solution Approach 1:
The invention selectively extracts only the necessary portions of the gate trace from critical surfaces using cutting processes. This partial extraction approach improves sealing and sliding properties on functional surfaces while minimizing the number of manufacturing steps compared to complete gate removal.
Solution Approach 2:
The cutting process is applied locally only to areas where the gate trace intersects with seat surfaces or sliding surfaces. This localized treatment maintains high reliability where needed while preserving manufacturing efficiency in other areas, avoiding unnecessary additional steps.
3Manufacturing precision
If additional finishing processes are applied to remove gate traces from critical surfaces, then the sealing and sliding properties are improved, but the manufacturing complexity and time increase
Solution Approach 1:
The invention uses cutting processes to extract gate traces from critical surfaces, achieving high surface quality and sealing properties. This extraction method is more efficient than traditional finishing processes and integrates smoothly into existing manufacturing workflows.
Solution Approach 2:
The cutting process is applied selectively only to regions where gate traces affect functional performance. This localized approach achieves high manufacturing precision on critical surfaces without adding complex finishing processes to the entire valve body, thereby controlling manufacturing complexity.
Data Source
AI summary
A control valve includes a housing, a valve body arranged in a valve chamber of the housing, and a support member fixed to the housing and supporting the valve body in the valve chamber. The valve body has a tubular shape into which the support member is inserted, and the valve body is slidable on the support member between a first position to close an inlet passage and a second position to close a drain passage. The valve body includes a skin layer forming an outer surface of the valve body, and a core layer under the skin layer. The outer surface of the valve body includes a core exposed portion where the core layer is exposed without being covered with the skin layer.