Forged Valve Disc Structure for Lower-Cost Pressure Relief Valves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pressure relief valves require significant material and manufacturing costs due to their complex geometry and material strength requirements, necessitating costly casting processes and extensive testing.
Innovation Solution
The design of a valve disc with a reduced material usage and optimized geometry for forging, featuring a circumferential wall and cylindrical recess to guide movement and engage with the valve stem, allowing for less material consumption and eliminating the need for pressure testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional casting processes are used to manufacture valve discs with complex geometry, then the valve disc can meet material strength requirements, but manufacturing costs and material usage increase significantly
Solution Approach 1:
The patent changes the geometric parameters of the valve disc by introducing a circumferential wall with height at least twice the thickness, creating a cylindrical cavity structure. This parameter change allows the valve disc to be manufactured using forging processes rather than casting, reducing manufacturing costs while maintaining structural integrity and material strength.
Solution Approach 2:
The valve disc is segmented into distinct functional portions: a base portion for engaging the valve seat, a circumferential wall portion for guiding movement, and a cylindrical cavity for receiving the valve stem. This segmentation allows each portion to be optimized for its specific function and manufactured efficiently through forging processes.
2Adaptability or versatility
If complex geometry is used in valve disc design, then functional requirements are met, but material usage and manufacturing complexity increase
Solution Approach 1:
The circumferential wall is designed with a thickness that is at least half its height, creating a thin-walled cylindrical structure. This thin-walled design reduces material usage while maintaining the structural integrity needed to guide valve disc movement and engage with the valve stem, eliminating the need for extensive pressure testing.
Solution Approach 2:
The patent introduces a vertical dimension by creating a circumferential wall with height at least twice the thickness, forming a three-dimensional cylindrical cavity structure. This dimensional change provides the necessary guidance and engagement functions while using less material compared to traditional solid or thick-walled designs.
3Reliability
If extensive pressure testing is performed on valve discs, then reliability is ensured, but manufacturing time and cost increase
Solution Approach 1:
The valve disc geometry itself, with its circumferential wall structure and cylindrical cavity, provides inherent structural integrity and guidance functions that eliminate the need for extensive pressure testing. The design is optimized for forging processes, which produce parts with fewer defects and higher reliability without requiring additional testing steps.
Data Source
AI summary
Valve discs for use with fluid valves are disclosed herein. An example valve disc for a fluid valve includes a base portion having a first side to engage a seat of the fluid valve and a second side opposite the first side, the second side being generally planar and having a centrally located recess to receive a valve stem. The valve disc further includes a circumferential wall extending away from a peripheral edge of the second side, an inner surface of the wall and the second side defining a cylindrical cavity, wherein a height of the circumferential wall is at least twice a thickness of the circumferential wall.