Modular Valve Assembly Mounting Plate for Leak-Resistant Injection Molding
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Solution Overview
Problem
Existing valve assemblies with injection-molded fluid connection units face challenges due to the need for multiple individual parts and complex assembly processes, which are costly and prone to leakage.
Innovation Solution
A valve assembly design featuring a fluid connection unit composed of at least two injection-molded connection blocks, where each block extends over multiple fluid valves and is mechanically connected to adjacent blocks and valves, reducing the number of individual parts and connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-piece fluid connection unit with multiple fluid connections arranged in several rows is injection molded, then the fluid connection unit can be manufactured as a single integrated part, but the mold parting plane cannot be properly positioned due to numerous undercuts, making injection molding extremely expensive or impossible
Solution Approach 1:
The fluid connection unit is divided into multiple connection blocks, each extending over only one or two fluid valves. This segmentation allows each block to be injection molded separately with a feasible mold parting plane position, avoiding the undercut problems that would occur with a single large connection unit spanning all fluid valves
Solution Approach 2:
Instead of arranging connection blocks in rows parallel to the fluid valve alignment (one dimension), the invention stacks connection blocks vertically (second dimension). Each connection block extends over fluid valves in the horizontal direction but is positioned at different vertical levels, allowing mold parting planes to be positioned between stacked blocks without creating undercuts
2Ease of manufacture
If the fluid connection unit is divided into multiple sub-units that are injection molded separately and then assembled, then injection molding becomes feasible, but the manufacturing process becomes complex, time-consuming, and costly with increased leakage risk at each joint
Solution Approach 1:
Multiple connection blocks are merged into a single integrated fluid connection unit through mechanical connection elements (such as integrally formed connection elements or inserted fasteners) that join the blocks together. This merging reduces the number of separate assembly steps compared to traditional sub-unit assembly while maintaining the injection molding feasibility of individual blocks
Solution Approach 2:
The connection blocks are designed with self-aligning features and integrated connection elements that automatically position and secure the blocks together during assembly. This self-service mechanism reduces the need for complex external assembly tools and procedures, decreasing assembly time and complexity
3Manufacturing precision
If multiple connection blocks are stacked vertically with each extending over one or two fluid valves, then the mold parting plane can be properly positioned for each block, but the connection blocks must be mechanically connected to maintain structural integrity
Solution Approach 1:
Connection blocks are nested vertically one above another, with each block containing or supporting connection elements that interface with adjacent blocks. This nesting arrangement allows the mold parting plane to be positioned at the interfaces between nested blocks, facilitating easy separation and molding while maintaining structural integrity through the nested connection mechanism
Data Source
AI summary
A valve assembly includes at least two fluid valves which are placed next to each other along a direction of alignment and each have a driving side and a fluid side. Each valve includes a fluid connection unit which extends along the direction of alignment over the fluid side of the fluid valves. The fluid connection unit is composed of at least two connection blocks each of which extends along the direction of alignment over the fluid valves and is provided with fluid connections. Each connection block is mechanically connected to the adjacent connection block and to the fluid valves, and the connection blocks are configured as injection-molded parts, and the mold parting plane of a connection blocks extends through the fluid connections of this connection block.