Manifold Plug Insert With Depth-Controlled High-Pressure Sealing
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Solution Overview
Problem
Existing plug and sealing systems face challenges in ease of installation, manufacturing complexity, and repeatability, particularly in sealing hydraulic manifolds under high pressure, with issues such as stem breakage and lack of depth control during installation.
Innovation Solution
A plug system featuring a tapered core and cylindrical sleeve, secured by a pull-rod mechanism, allows for easy installation using an installation device with depth control, ensuring repeatable sealing and resistance to high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a stem is used in the plug to act similar to a pop rivet, then the plug can be installed in a hole, but the manufacturing of the stem becomes complicated and expensive as it must break off at the appropriate force
Solution Approach 1:
The patent removes the stem component entirely from the plug design. Instead of using a stem that breaks off during installation, the plug uses a simple cylindrical body with an expanded end that directly engages with the hole, eliminating the complex stem manufacturing and breakage control requirements.
Solution Approach 2:
The plug is designed as a simple, inexpensive component without expensive stem mechanisms. The plug is installed once and remains in place, functioning as a disposable sealing solution that eliminates the need for complex reusable installation mechanisms.
2Device complexity
If manual activation is used for installing the plug, then the tool is simple, but there is no mechanical power or depth control for controlling the installation depth of the insert
Solution Approach 1:
The patent introduces a drive mechanism as an intermediary between the operator and the plug installation process. This drive provides mechanical power and includes a depth control feature that acts as a mediator to ensure precise installation depth without requiring complex tool structures.
3Ease of manufacture
If a rivet system is used for sealing, then the plug can be installed in holes, but the stem must break off at the appropriate force which complicates manufacturing
Solution Approach 1:
The patent extracts the stem component from the rivet system design, leaving only the essential plug body. This simplifies manufacturing by eliminating the need to create and control stem breakage, while the plug body itself provides the sealing function through its expanded end geometry.
4Reliability
If existing plug systems are used, then sealing can be achieved, but repeatability of installation is lacking
Solution Approach 1:
The patent incorporates depth control feedback mechanisms in the installation device that provide visual or mechanical feedback during installation. This ensures that each plug is installed to the precise same depth, achieving repeatable installation results while maintaining reliable sealing performance.
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 system enables efficient, repeatable, and secure sealing of holes in manifolds, capable of withstanding pressures up to 40,000 psi, with improved manufacturing efficiency and reduced complexity.
Implementation Method 1
The core is pulled into the cylindrical sleeve to radially expand the cylindrical sleeve against the hole
Data Source
AI summary
The present disclosure relates to an insert and system of installing the same. The insert includes a tapered core and a cylinder. The core releasably secures to an installation device which includes a depth stop or a depth control to control the installation depth of the insert. The insert may be provided in a tray that allows for easier handling of the inserts and installation thereof in installation holes, for example in a hydraulic manifold. In some cases, the core includes a threaded hole to releasably secure the insert to the installation device, thus allowing the installation device to pull the core into the cylinder. The core and cylinder may be made of metallic materials such as steels, steel alloys and others. In some cases the insert can withstand blow out pressures of 40,000 psi or higher.