Lined Butterfly Valve Disk Structure for Warpage-Tolerant Sealing
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Solution Overview
Problem
Lined butterfly valves with large diameters face challenges in maintaining uniform resin lining thickness, leading to potential fluid permeation and leakage due to warpage of the core metal, especially near the valve blade side, where the lining thickness may be insufficient or excessive, and forming precise seal widths on the outer circumference is difficult without high-accuracy core metal shaping.
Innovation Solution
The design features a valve disk with front/back-side lining parts and an outer circumferential lining part, including a convex part, where the lining thickness accounts for maximum warp width and provides a predetermined crush thickness, ensuring uniformity and sealability, along with washers for maintaining surface pressure and alignment, even if warpage occurs, and a method of manufacturing where the core metal is fixed within a molding die to ensure accurate lining formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the core metal is made with large diameter to increase valve size, then the valve capacity increases, but warpage occurs on the valve blade side causing non-uniform lining thickness
Solution Approach 1:
The patent applies preliminary action by adding a support structure (ribs or trusses) to the core metal before the lining process. This preventive measure counteracts the warpage that would occur during lining, ensuring the core metal maintains its flatness throughout the manufacturing process. The support structure is designed to bear the weight of the core metal and prevent deformation before the resin lining is applied.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating a support structure that absorbs and distributes the stress and weight of the large-diameter core metal. This cushioning effect prevents warpage from developing during the lining process, maintaining uniform lining thickness across the entire surface including the valve blade side.
2Ease of manufacture
If the core metal is supported in lateral orientation for lining process, then the entire surface including front and back surfaces can be lined, but the valve blade side flexes downward by self-weight causing insufficient lining thickness
Solution Approach 1:
The patent applies preliminary action by installing the support structure (ribs or trusses) on the core metal before the lining process begins. This preliminary reinforcement prevents the valve blade side from flexing downward during lining, ensuring uniform resin thickness is achieved across all surfaces including the previously problematic valve blade side.
Solution Approach 2:
The support structure acts as an intermediary element between the core metal and the lining resin. It mediates the mechanical stress distribution, preventing direct flexure of the core metal under its own weight while allowing the lining process to proceed on the lateral orientation. This intermediary structure ensures both manufacturing accessibility and precision.
3Manufacturing precision
If the core metal is shaped with high accuracy to ensure uniform seal width, then the outer circumferential seal surface width becomes uniform, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies preliminary action by adding the support structure before the lining process to maintain core metal flatness. This preliminary reinforcement ensures that the outer circumferential seal surface maintains its intended geometry and uniform width without requiring excessively high initial shaping precision of the core metal itself.
Solution Approach 2:
The patent changes the structural parameters of the core metal by incorporating ribs or trusses, which fundamentally alter how the core metal behaves under load. This parameter change allows the core metal to maintain geometric stability and uniform seal surface width without requiring the core metal to be shaped with extremely high initial precision, thereby reducing manufacturing complexity.
Data Source
AI summary
A lined butterfly valve and manufacturing method, the lined butterfly valve including a valve disk (2) with a core metal (20) covered with a lining layer (22) provided rotatably inside a body (3) by a stem (5). The lining layer includes a front/back-side lining part (32) provided on each of front and back sides of the core metal and an outer circumferential lining part (33) provided on an outer circumferential side of the core metal. The front/back-side lining part is provided on each of the front and back sides of the core metal in which no occurrence of warpage is assumed so as to have a thickness T1, and the outer circumferential lining part has a thickness T2 from an outer circumferential end of the core metal to a tip seal surface of an outer circumferential end of the valve disk.