Manifold Plug Insert with Depth-Controlled Expansion Sealing
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Solution Overview
Problem
Existing plug and sealing systems for manifolds are complex and expensive to manufacture, lack depth control during installation, and do not provide repeatable or easy installation methods, especially for hydraulic manifolds under high pressures.
Innovation Solution
A plug system featuring a tapered core and cylindrical sleeve with a threaded hole, secured to an installation device that includes a depth stop and pull-rod mechanism for controlled radial expansion, allowing for easy handling and repeatable installation in a tray, and capable of withstanding high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rivet system with a stem is used to install the plug, then the plug can be installed in the hole, but the manufacturing process becomes complicated and expensive
Solution Approach 1:
The invention removes the complex stem component from the plug assembly. Instead of using a rivet system with a stem that breaks off during installation, the patent uses a simple plug body with an expansion mechanism that eliminates the need for a separate stem, thereby simplifying manufacturing while maintaining installation capability
Solution Approach 2:
The plug is designed as a disposable component that is installed and then remains in place to seal the hole. The simplicity of the plug design without a reusable stem allows for cost-effective manufacturing while achieving the sealing function in a single-use application
2Ease of operation
If a hand-activated tool is used to install the plug, then the installation can be performed manually, but there is no depth control for controlling the installation depth
Solution Approach 1:
The invention introduces a depth control mechanism as an intermediary component between the manual tool and the plug. This mechanism provides the necessary depth control precision while allowing the installation to remain manually operated, bridging the gap between ease of operation and installation precision
Solution Approach 2:
The depth control is pre-configured on the installation tool before the plug is installed. This preliminary setup ensures that the correct installation depth is achieved without requiring complex real-time adjustments during the manual installation process
3Reliability
If a complex stem breaking mechanism is used, then the plug can be installed with proper force, but the installation process becomes time-consuming
Solution Approach 1:
The plug is designed with a self-expanding mechanism that automatically applies the necessary installation force when installed. The expansion mechanism self-regulates the force applied to seal the hole, eliminating the need for complex stem breaking mechanisms and reducing installation time while maintaining reliable sealing force
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 cost-effective installation of plugs in manifolds, ensuring reliable sealing and resistance to high pressures, with the ability to repair damaged threads in hydraulic systems.
Implementation Method 1
the pull-rod is retracted by the drive to pull the core into the cylindrical sleeve thereby radially expanding the cylindrical sleeve against the hole
Implementation Method 2
The core may include a threaded hole to releasably secure the insert to the installation device
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.