Manifold Plug Insert with Depth-Controlled Radial Sealing
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Solution Overview
Problem
Existing plug and sealing systems for manifolds are complex and costly to manufacture, and lack repeatable installation and depth control, particularly for hydraulic applications.
Innovation Solution
A plug system with a tapered core and cylindrical sleeve, where the core is secured to an installation device with depth control, allowing for easy handling and installation, and featuring a threaded hole for secure attachment, enabling radial expansion against the hole for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rivet system with a stem that breaks off during installation is used, then the plug can be installed in a hole, but the manufacturing process becomes complicated and expensive
Solution Approach 1:
The patent removes the complex stem component entirely from the plug design. Instead of using a rivet system with a breaking stem, the invention uses a simple cylindrical plug that is inserted directly into the hole and secured through radial expansion, eliminating the need for a separately manufactured stem assembly
Solution Approach 2:
The patent changes the installation mechanism from a breaking-stem rivet system to a radial expansion system. The plug incorporates an expansion mechanism that allows it to be inserted in a relaxed state and then expanded radially to secure itself, fundamentally changing the installation parameters and eliminating manufacturing complexity
2Manufacturing precision
If manual activation without mechanical power is used, then the tool is simple, but installation depth control is lacking
Solution Approach 1:
The patent introduces a depth control mechanism that acts as an intermediary between the manual activation force and the plug installation. This mechanism provides mechanical advantage and precise depth control without requiring complex powered systems, allowing accurate depth measurement and control during manual installation
3Ease of operation
If a threaded hole extending all the way through the socket is used, then the screw element can engage the sleeve, but the screw element remains in the hole after installation
Solution Approach 1:
The patent segments the fastening mechanism into distinct functional zones: an engagement zone with internal threads for securing the plug to the installation tool, and a sealed zone where the radial expansion creates the seal. This segmentation allows the threaded portion to be contained within the plug body rather than extending through the sealing interface
Solution Approach 2:
The patent nests the threaded hole within the plug body structure itself, rather than having it extend through the sealing interface. The threads are contained within the plug's internal volume, allowing the external surface to maintain its sealing capability while still providing secure engagement with the installation tool
4Strength
If a conical or tapered surface on the nut stem is used, then the sleeve can be expanded against the hole, but the installation device complexity increases
Solution Approach 1:
The patent incorporates a tapered surface on the expansion mechanism that converts axial insertion force into radial expansion force. This geometric feature allows the plug to be secured firmly against the hole wall while maintaining a relatively simple installation device, as the taper itself performs the force transformation
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 facilitates easier and repeatable installation of plugs in holes, withstanding high pressures, and providing reliable sealing and resistance to leakage, even in hydraulic manifolds, with adjustable installation depth and pressure control.
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 and sleeve are sized so that the core can be press-fit into the sleeve
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.