Plastic-Coated Butterfly Valve Disk for Corrosion and Weight Reduction
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Solution Overview
Problem
Conventional butterfly valves made entirely of steel are prone to corrosion, heavy, and costly, making them difficult to precisely manufacture and limiting mass production due to their high strength and processing challenges.
Innovation Solution
A butterfly valve design featuring a metal disk body with two plastic layers, where the first plastic layer is formed through insert molding and has a higher melting point than the second plastic layer, enhancing corrosion resistance and reducing weight while maintaining strength, allowing for precise processing and mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a butterfly valve is made entirely of steel, then its strength is high, but it is easy to be corroded, its weight is heavy and its manufacture cost has increased
Solution Approach 1:
The butterfly valve combines a metal disk body (steel) with plastic layers (such as PTFE or other corrosion-resistant polymers) to create a composite structure. The metal provides structural strength while the plastic coating provides corrosion and chemical resistance, resolving the contradiction between strength and corrosion resistance.
Solution Approach 2:
The plastic layers are applied selectively to the surfaces of the metal disk body that are exposed to corrosive fluids, while the internal structural components remain as metal. This localized application provides corrosion protection where needed while maintaining the overall strength of the valve.
2Strength
If a butterfly valve is made entirely of steel, then its strength is high, but its weight is heavy
Solution Approach 1:
The composite structure replaces portions of the heavy metal with lighter plastic materials while maintaining structural integrity. The metal disk body provides the necessary strength framework, while the plastic layers reduce overall weight and provide surface protection.
3Strength
If a butterfly valve is made entirely of steel, then its strength is high, but its manufacture cost has increased
Solution Approach 1:
The composite construction allows for more efficient manufacturing processes. The plastic layers can be molded or coated onto the metal substrate, enabling mass production techniques that reduce labor costs and manufacturing time compared to machining solid steel valves.
4Strength
If a butterfly valve is made entirely of steel, then its strength is high, but it is difficult to process precisely
Solution Approach 1:
The plastic layers can be molded with high precision to achieve smooth surfaces and accurate dimensions, complementing the metal substrate. This combination allows for precise processing that would be difficult or expensive to achieve with solid steel alone.
5Strength
If a butterfly valve is made entirely of steel, then its strength is high, but it is impossible to achieve mass production
Solution Approach 1:
The composite structure enables mass production through standardized manufacturing processes. The metal disk bodies can be produced using stamping or forming techniques, and the plastic layers can be applied through molding or coating processes that are easily automated, allowing for high-volume production while maintaining strength requirements.
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 solution provides a butterfly valve with improved corrosion resistance, reduced weight, and lower manufacturing costs, enabling extended lifespan and efficient mass production while maintaining similar strength to steel valves, with a weight reduction from 1 kg to 350 g.
Implementation Method 1
a first plastic layer formed of a first plastic; and a second plastic layer formed of a second plastic on the first plastic layer, wherein a melting point of the first plastic layer is higher than a melting point of the second plastic layer
Data Source
AI summary
A butterfly valve which may enhance corrosion resistance or acid resistance with keeping its strength, have light weight and realize mass production, and method of manufacturing the same. are disclosed. The butterfly valve comprises a body in which an inserting space is formed and a disk inserted into the inserting space of the body, wherein fluid flow is opened or closed in response to rotation of the disk. Here, the disk includes a disk body formed of a metal, and at least one plastic layer formed on the disk body.