Double-Injected Mini Valve Core for Low-Torque Sealing
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Solution Overview
Problem
The manual assembly of mini valves for low-pressure applications is time-consuming and costly due to the complexity of positioning and ensuring correct sealing of o-rings, which often results in leakage and increased quality control needs, as automatic assembly with precise positioning of o-rings is difficult and costly.
Innovation Solution
A new mini valve design integrates the sealing material with the Valve Core using a double injection technique, allowing for automatic assembly and eliminating the need for manual o-ring placement, with a thermoplastic elastomer layer ensuring watertight sealing and a locking mechanism for automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual assembly with customized assembly jigs is used to position o-rings, then sealing quality can be ensured, but production time and cost increase significantly
Solution Approach 1:
The patent combines the valve core and sealing material into a single integrated component produced by double injection molding. The first injection creates the valve core, and the second injection adds the sealing material directly onto the core, eliminating the need for separate o-ring assembly operations and reducing production steps while maintaining sealing quality
Solution Approach 2:
The sealing material is pre-positioned and molded onto the valve core during the injection process before assembly. This preliminary action ensures correct sealing material placement and eliminates the need for manual positioning during final assembly, thereby improving both sealing reliability and production efficiency
2Reliability
If manual assembly is used to position o-rings, then correct sealing can be achieved, but labor cost and production complexity increase
Solution Approach 1:
The valve core and sealing material are merged into a single integrated part through double injection molding. This eliminates multiple separate components (valve core, o-rings, assembly jigs) and simplifies the assembly process to a single insertion step, reducing both labor requirements and production complexity while maintaining sealing correctness
Solution Approach 2:
The double injection molding process automatically positions and secures the sealing material onto the valve core without manual intervention. The process self-regulates the placement and fixation of sealing elements, eliminating the need for manual assembly operations and specialized assembly equipment
3Ease of manufacture
If o-rings are held by elasticity, then assembly is simplified, but automatic assembly with precise positioning becomes difficult and costly
Solution Approach 1:
The patent changes the state of the sealing material from elastic o-rings to thermoplastic material that can be molded in a fixed shape during injection. This parameter change allows the sealing material to be precisely positioned and fixed during the molding process, enabling automatic assembly while maintaining assembly simplicity through the integrated design
4Adaptability or versatility
If separate production of valve core and o-rings is used, then material selection is optimized, but assembly time and quality control requirements increase
Solution Approach 1:
The patent uses composite materials by combining two different polymers through double injection molding: the first injection uses a polymer suitable for the valve core, and the second injection uses a polymer with sealing properties. This allows optimization of material selection for both components while producing them as a single integrated part, eliminating assembly time and quality control requirements for separate components
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 simplifies the assembly process, ensures consistent and correct sealing without manual intervention, reduces production costs, and enhances the reliability of the sealing mechanism by integrating the sealing material directly with the Valve Core, thereby reducing leakage risks and operational complexity.
Implementation Method 1
the thermoplastic elastomer is added on the interference surface of the Valve Core (1) to seal between the cylindrical Valve Body (2) and the Valve Core (1)
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
The invention in question is a sealing method for injection molded polypropylene plastic valves, allowing simple and safe sealing of the valve in closed, semi-open and open positions without having to manually add the sealing material, as well as the sealing rib related to the method. The type of valve comprises of two parts (see Figure 1): a) The Valve Body (2) with inlet (7), outlet (8) and a chamber for the Valve Core (1) b) The Valve Core (1), with the handle (4), valve opening (6) and sealing material (3) The invented method is using double injection techniques to shape the polypropylene Valve Core (1) of the valve in the first injection stage and then apply the thermoplastic elastomer sealing material (3) to the surface of the polypropylene Valve Core (1) in the second stage. In this way the Valve Core (1) and the Sealing Material (3) is made as one part in one single process, but with two separate injection stages. The Sealing Material (3) which is adhered to the surface of the Valve Core (1) is creating a sealing barrier where there is interference between the Sealing Material (3) and the Valve Body (2). The actual sealing is made by a protruded Sealing Rib (5) at the edges of the area of the Sealing Material (3). The elastomer Sealing Rib (5), which will seal against the inner surface of the Valve Body (2), is carefully measured to ensure proper sealing in all open/closing stages, while at the same time not adding too much friction between the parts. This way proper sealing is achieved, without having to increase the torque required to open and close the valve.