Inflatable Hose Valve Bonding With TPU Base for Leak-Proof Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for securing valves on flexible tube sections are complex and prone to unintended removal, particularly in thermoplastic polyurethane-based tubes, which are more expensive and require improved adhesion techniques.
Innovation Solution
A valve comprising a tubular shaft and a thermoplastic polyurethane valve base, where the valve base is adhesively connected around the entire periphery to the shaft, with surface treatments like anodization and plasma treatment enhancing adhesion, and a process involving injection molding or extrusion for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve is secured by clamping the flexible tube wall between the valve end and a pressure sleeve, then the connection is achieved, but the valve is susceptible to unintended extraction and the process is complicated
Solution Approach 1:
The valve base is merged with the shaft through adhesive bonding around the entire periphery, creating an integrated unit that eliminates the need for separate clamping components like pressure sleeves and washers. This merging reduces the number of parts and simplifies the securing process while maintaining reliable attachment to the flexible tube section
Solution Approach 2:
An adhesive intermediary substance is introduced between the valve base and the shaft to create a strong bond. This adhesive layer allows for reliable attachment without mechanical clamping, preventing unintended extraction while simplifying the overall construction by eliminating complex fastening mechanisms
2Ease of manufacture
If adhesive bonding is used to connect the valve base to the shaft, then the connection is simplified, but the adhesion strength may be insufficient without surface treatments
Solution Approach 1:
Surface treatments such as anodization of the shaft and plasma treatment of the valve base are performed in advance of adhesive bonding. These preliminary actions prepare the surfaces by increasing their surface area and creating chemically active sites, ensuring strong adhesion before the adhesive is applied. This preliminary preparation maintains ease of manufacture by integrating into the production process while guaranteeing bond strength
Solution Approach 2:
The physical and chemical parameters of the bonding surfaces are changed through anodization and plasma treatment. Anodization creates a porous oxide layer on metal shafts, while plasma treatment modifies the surface energy and chemistry of polymer valve bases. These parameter changes dramatically improve adhesive bond strength while maintaining process simplicity
3Strength
If thermoplastic polyurethane is used for the flexible tube section, then higher load capacity and lower weight are achieved, but production costs increase
Solution Approach 1:
The valve base is manufactured from the same thermoplastic polyurethane material as the flexible tube section, creating material homogeneity. This allows the valve to be produced using the same extrusion or injection molding processes as the tube itself, eliminating the need for separate material inventories, different manufacturing equipment, and complex assembly procedures. The homogeneous material approach maintains high strength properties while reducing overall production costs through process standardization
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 provides a robust, leak-proof connection between the valve and flexible tube section, ensuring secure attachment and preventing air leakage during inflation, while reducing production costs and improving accessibility.
Implementation Method 1
a valve base (20), connected adhesively and around the entire periphery to an end of the shaft (10)
Implementation Method 2
surface treatments like anodization and plasma treatment enhancing adhesion
Implementation Method 3
surface treatments like anodization and plasma treatment enhancing adhesion
Implementation Method 4
a process involving injection molding or extrusion for secure bonding
Implementation Method 5
a process involving injection molding or extrusion for secure bonding
Data Source
AI summary
Valve for an inflatable flexible tube section comprising a tubular shaft, and also a valve base, connected adhesively and around the entire periphery to an end of the shaft, wherein the valve base has been manufactured from a thermoplastic polyurethane.