Monobloc Ball Valve Structure to Eliminate Welded Joints
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Solution Overview
Problem
Traditional ball valves in refrigeration systems require high production times and complex welding processes to ensure mechanical and hydraulic performance under high operating pressures, leading to increased thermal stresses and production costs.
Innovation Solution
A ball valve design featuring a monobloc body and cap without welds, manufactured using a single lost-wax molding process, with circumferential welding for sealing, reducing the number of welds and simplifying assembly while maintaining high mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-component ball valves with welds are used, then mechanical connection and hydraulic seal are guaranteed, but production time increases and thermal stresses increase
Solution Approach 1:
The patent merges the body and connecting elements into a single monobloc structure manufactured by lost-wax molding, eliminating the need for separate welding operations between components. This integration maintains hydraulic seal reliability while dramatically reducing production time by removing multiple welding steps and associated quality control requirements.
Solution Approach 2:
The invention extracts and eliminates the welding process entirely from the manufacturing sequence by adopting a monobloc construction approach. By removing the welding operation, the patent eliminates thermal stresses, distortion risks, and the time-consuming nature of welding while preserving the structural integrity and sealing capability of the valve.
2Strength
If multiple components are welded together, then mechanical connection is achieved, but device complexity and production cost increase
Solution Approach 1:
The patent combines multiple components (body, connecting elements, sealing surfaces) into a single monobloc structure that is molded as one piece. This eliminates the complexity of assembling and welding separate components while maintaining or enhancing mechanical strength through the integrated monolithic construction.
3Reliability
If circumferential welding is used for sealing, then hydraulic seal is ensured, but thermal stresses are generated
Solution Approach 1:
The invention removes the circumferential welding operation entirely by designing the monobloc body with integrated sealing surfaces that require no welding for assembly. This eliminates the source of thermal stresses while maintaining hydraulic seal integrity through precision molding and inherent seal geometry.
Solution Approach 2:
The patent replaces permanent welding joints with a molded monobloc structure that achieves sealing through its geometry and material properties rather than through thermal processing. This approach avoids the harmful thermal effects of welding while achieving the same sealing function.
Data Source
AI summary
A ball valve (1; 100) comprising a body (2; 102) delimiting an internal cavity, a plug (3; 103) configured to be permanently connected to the body (2; 102), for partially closing the internal cavity, a ball shutter (5) housed in the internal cavity, a first connecting element (18; 118) configured as a hollow tubular element in fluid communication with the ball shutter (5) and wherein the plug (3; 103) comprises a second connecting element (20; 120) configured as a hollow tubular element in fluid communication with the ball shutter (5), wherein the body (2; 102) and the first connecting element (18; 118) together define a monobloc body and wherein the plug (3; 103) and the second connecting element (20; 120) together define a monobloc body without welds.