Laser-Welded Water Valve Guide Tube for Leak-Resistant Assembly
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Solution Overview
Problem
Existing methods for joining guide tubes to water valve housings, such as spin welding and ultrasonic welding, require complex tooling, tight tolerances, and can lead to increased part count, cost, and potential leaks or diaphragm herniation, making them inefficient and costly.
Innovation Solution
The use of laser welding to directly bond guide tubes to housings with flat axially facing mating surfaces, eliminating the need for a spin ring and allowing for more predictable material flow and reduced tooling complexity, while maintaining precise angular and height tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spin welding is used to join guide tube to housing, then the guide tube can be securely attached, but the part count increases due to the spin ring and tooling complexity increases
Solution Approach 1:
The spin ring is extracted/removed from the assembly by using a different joining method (ultrasonic welding) that achieves the same secure attachment function without requiring the additional spin ring component, thereby reducing part count while maintaining joint strength
Solution Approach 2:
The mechanical spin welding process is replaced with ultrasonic welding, which uses ultrasonic vibrations to create the joint. This substitution eliminates the need for complex spin ring tooling while achieving secure attachment of the guide tube to the housing
2Strength
If spin welding is used to join guide tube to housing, then the guide tube can be securely attached, but the manufacturing cost increases due to tight tolerances and complex tooling
Solution Approach 1:
The spin ring component and its associated complex tooling are extracted from the manufacturing process, replacing them with ultrasonic welding technology that achieves secure attachment with simpler, more cost-effective tooling and relaxed tolerance requirements
Solution Approach 2:
The mechanical spin welding system with its complex tooling and tight tolerance requirements is replaced with an ultrasonic welding system that uses vibrational energy to create strong joints with simpler tooling and more economical manufacturing
3Ease of operation
If spin welding is used to join guide tube to housing, then the guide tube can be attached, but achieving specific angular orientation and height tolerance becomes difficult
Solution Approach 1:
The mechanical spin welding process, which struggles with angular orientation and height tolerance, is replaced with ultrasonic welding that uses a horn to apply precise vibrational energy at the joint interface, enabling better control over alignment, angular orientation, and height tolerance during the welding process
4Strength
If spin welding is used to join guide tube to housing, then the guide tube can be attached, but leak paths may develop at the interfacing surfaces
Solution Approach 1:
The spin welding process is replaced with ultrasonic welding, which creates a more reliable seal by using high-frequency vibrations to melt and fuse the plastic materials at the molecular level, eliminating micro-gaps and potential leak paths that can occur with mechanical interlocking methods
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
This approach reduces part count and manufacturing costs, enhances tolerance control, and minimizes the risk of leaks or diaphragm failure, resulting in a more efficient and cost-effective water valve design.
Implementation Method 1
A laser welder is utilized to bond the guide tube to the housing
Implementation Method 2
the weld interface features must have tight tolerances to accurately and precisely control the amount of dimensional changes as a result of the melting of the material
Implementation Method 3
A solenoid coil is attached to the exterior of the guide tube, and provides the electromagnetic force necessary to move the armature within the guide tube
Implementation Method 4
The housing, guide tube, and spin ring are made of plastic and they have a specific geometry that promotes melting of the material and allows for travel of expelled melted material
Implementation Method 5
This method relies on frictional forces created by ultrasonic pulses to heat mating parts and weld the same at their interface
Implementation Method 6
This method relies on frictional forces created by ultrasonic pulses to heat mating parts and weld the same at their interface
Data Source
AI summary
A water valve, guide tube for a water valve, and associated method are provided. The water valve includes a housing and the guide tube is installed on the housing via laser welding. The guide tube and housing each provide axially facing mating surfaces which abut one another in a pre-bonded configuration. In a post-bonded configuration, a laser weld joint is formed at the interface between the mating surfaces. The joint forms a portion of an outer periphery of the housing.