Hydraulically Formed Metal Casing for Plumbing Valves
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Solution Overview
Problem
Plumbing devices such as valves and flow meters made from brass or bronze are heavy, bulky, and costly due to the need for complex manufacturing processes and material usage, which increases production costs and end-user prices.
Innovation Solution
A plumbing device comprising a hydraulically formed metal tubing casing with a cartridge containing operational components, where the cartridge is retained within the casing using engagement mechanisms like rolled formations or screws, allowing for fluid communication and reduced material usage, thus minimizing manufacturing steps and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If metal tubing is hydraulically formed to create a casing with integrated formations and openings, then the device weight and bulkiness are reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies hydraulic forming to shape metal tubing into the device casing. High-pressure fluid is used to form the tubing into the desired three-dimensional configuration with integrated formations, openings, and cartridge accommodation features in a single manufacturing step, reducing weight and eliminating the need for separate machining operations.
Solution Approach 2:
The hydraulic forming process changes the physical parameters of the metal tubing through high-pressure fluid application, transforming it from a simple tube into a complex casing structure with integrated features. This parameter change enables weight reduction while maintaining structural integrity.
2Device complexity
If the cartridge is retained within the casing using engagement mechanisms, then the device assembly is simplified, but the manufacturing steps increase
Solution Approach 1:
The device is divided into two main segments: a reusable casing and a replaceable cartridge containing operational components. The casing is hydraulically formed with integrated engagement mechanisms (protrusions and recesses) that securely retain the cartridge. This segmentation simplifies assembly and enables easy cartridge replacement while maintaining a streamlined manufacturing process for the casing.
Solution Approach 2:
The cartridge is nested within the casing, with the casing providing structural support and fluid connections while the cartridge contains the operational components. The engagement mechanisms create an integrated nested structure that simplifies assembly while the modular nature allows for efficient manufacturing of separate components.
3Adaptability or versatility
If openings, projections and recesses are provided in the housing during manufacture, then the operational components can be accommodated, but the manufacturing costs increase
Solution Approach 1:
Multiple features (openings, projections, recesses, and cartridge accommodation spaces) are merged into a single hydraulic forming operation. The metal tubing is formed in one continuous process to create all necessary structural features and fluid passages, eliminating the need for separate machining steps and reducing manufacturing costs while maintaining full adaptability for operational components.
Solution Approach 2:
The hydraulically formed casing serves multiple functions simultaneously: it provides structural support, creates fluid passages, accommodates operational components, and integrates engagement mechanisms for the cartridge. This multi-functionality is achieved through the versatile hydraulic forming process that can create complex three-dimensional features in a single operation.
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 results in a lighter, more efficient plumbing device with reduced manufacturing complexity and costs, while maintaining effective fluid control and flow management.
Implementation Method 1
a casing hydraulically formed from metal tubing to have a wall surrounding a void interior
Data Source
AI summary
A device for a plumbing installation, the device, for example, may be a valve, such as valve (1), or a fluid flow meter (6), and has a casing (10) that is hydraulically formed from metal tubing so as to have a wall surrounding a void interior. The casing (10) is provided with one or more formations, such as shoulders (64) and (65) and at least one inlet opening (14) and at least one outlet opening (18). A cartridge (12) is at least partly located in the void interior of the casing (10). The cartridge (12) has at least two openings, being a first opening (20) and a second opening (22). Seals (46), (48) and (50) are provided between the casing (10) and the cartridge (12). The cartridge (12) is accommodated in the casing (10) by the one or more formations of the casing (10). The cartridge (12) is provided with the operational components of the device (1). The inlet opening (14) of the casing (10) and the first opening (20) of the cartridge (12) are in fluid communication. Similarly, the second opening (22), of the cartridge (12) and the outlet opening (18) of the casing (10) are in fluid communication. A fluid flow path is thereby created through the device (1) from the inlet opening (14) of the casing (10), through the cartridge (12), to the outlet opening (18) of the casing (10).