Net-Shape Plastic Pump Housing With Non-Intersecting Ports
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Solution Overview
Problem
Conventional methods for manufacturing plastic pump housings for food applications require significant secondary machining, exceeding glass fiber exposure limits and increasing costs, while existing molds and techniques fail to produce net-shape molded housings suitable for high-temperature conditions without intersecting geometry.
Innovation Solution
A method using molds and cores configured to produce net-shape molded plastic pump housings with fluid inlet, outlet, and pressure relief valve ports, where none of the ports have intersecting geometry, allowing for minimal secondary machining and compliance with glass fiber exposure limits, utilizing a cross-tube insert for flow communication between the inlet and relief valve ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molds and molding techniques are used to manufacture plastic pump housings, then the housing can be produced, but significant secondary machining is required which exceeds glass fiber exposure limits
Solution Approach 1:
The mold and core configuration is designed in advance to produce ports with non-intersecting geometry, so that the housing is molded ready for use with minimal secondary machining. The ports are positioned and shaped during the molding process itself, eliminating the need for extensive post-molding operations that would expose glass fibers.
Solution Approach 2:
The housing is divided into multiple ports (inlet, outlet, relief valve) that are independently configured in the mold and core system. Each port is formed by specific mold cavities and core components, allowing them to be positioned without intersecting geometry, thus avoiding the need for complex secondary machining.
2Ease of manufacture
If plastic materials are used to reduce manufacturing costs and eliminate lead, then cost reduction is achieved, but the materials must withstand high temperatures exceeding 149°C which limits material selection
Solution Approach 1:
Glass filled plastics are used as composite materials that combine the cost advantages and lead-free benefits of plastic with the high temperature resistance provided by glass fiber reinforcement. The glass fibers enhance the thermal stability and mechanical strength of the plastic, enabling it to withstand temperatures exceeding 149°C while maintaining the cost and safety advantages of plastic materials.
3Manufacturing precision
If significant secondary machining is performed on the molded housing, then port geometry can be achieved, but the glass fiber exposure on wetted surfaces exceeds the one inch limit
Solution Approach 1:
The port geometry is established during the molding process itself through properly configured mold cavities and core components. The ports are formed with their final geometry in the molding step, eliminating the need for secondary machining that would expose glass fibers on the wetted surfaces.
Solution Approach 2:
The glass fibers, which could be harmful if exposed on wetted surfaces through machining, are instead utilized as a beneficial reinforcement within the plastic matrix during molding. The molding process encapsulates the glass fibers within the housing structure, preventing their exposure on port surfaces while still providing the high temperature resistance benefits.
Data Source
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AI summary
A method of making a pump housing that is net-molded and immediately assumes its final shape and design specification without requiring more than de minimis secondary machining processes. The method utilizes molds and cores configured such that none of the fluid ports of the housing produced using the molds and cores have any intersecting geometry. The net-molded pump housing may also include a cross-tube insert providing flow communication between a fluid inlet port and a pressure relief port.