Poppet Valve Welded Stem Protrusions
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Solution Overview
Problem
Current methods for producing poppet valves with wings on combustion engine stems are complex, require additional material removal, and necessitate the same material for the wings and valve body, leading to inefficiencies and challenges in machining high alloy materials.
Innovation Solution
A poppet valve production method involving welding to form protrusions on the valve stem using a welding process, allowing for different materials and shapes, with the option to vary the height and width of the protrusions and their inclination, and using laser welding with powder materials, reducing the need for extensive machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods (upsetting, forging, machining) are used to produce poppet valves with wings, then the wings can be formed on the valve stem, but the production process becomes complicated and requires additional machining steps that remove material
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (upsetting, forging, machining) with a welding-based approach. Material is deposited onto the valve stem using welding processes to form the wings, eliminating the need for complex mechanical forming and material removal operations. This substitution of mechanical systems with welding technology directly resolves the contradiction by simplifying the production process while reducing complexity.
Solution Approach 2:
The patent changes the fundamental parameter of material joining from mechanical deformation (upsetting/forging) to thermal deposition (welding). By altering the process parameter from cold/mechanical working to thermal/welding working, the production method achieves simpler工艺流程 and eliminates multiple machining steps, thereby resolving the complexity issue.
2Loss of substance
If traditional machining methods are used to form wings on the valve stem, then the wings can be created, but additional material needs to be removed in machining steps
Solution Approach 1:
Instead of starting with excess material and removing it through machining to create the wings, the patent inverts the approach by starting with the base valve stem and adding material through welding to build the wings. This inversion from subtractive manufacturing to additive manufacturing eliminates material removal entirely, directly resolving the contradiction between material loss and manufacturing efficiency.
Solution Approach 2:
The patent eliminates the need to discard material through machining removal. By using welding to add material rather than remove it, the process recovers material efficiency by utilizing deposited material fully, thereby resolving the contradiction between material loss and manufacturing efficiency.
3Adaptability or versatility
If the same material is used for the valve body and wings, then material compatibility is ensured, but flexibility in optimizing wing properties is limited
Solution Approach 1:
The patent applies local quality by allowing different materials to be used for different parts of the valve. The welding process enables deposition of material with specific properties (such as different alloy composition, hardness, or thermal properties) on the wings while maintaining the original valve body material. This local differentiation of material properties resolves the contradiction between material selection flexibility and material uniformity.
Solution Approach 2:
The patent utilizes composite material construction by combining the base valve stem material with deposited welding material to create a composite structure. The wings consist of deposited material that can be selected independently from the valve body material, enabling optimization of wing properties (such as wear resistance, thermal conductivity, or strength) while maintaining overall structural integrity. This composite approach directly resolves the contradiction between material flexibility and composition stability.
4Reliability
If high alloy materials are used for the valve, then performance is improved, but machining becomes more difficult
Solution Approach 1:
The patent replaces mechanical machining operations with welding deposition to form the wings on high alloy valve stems. By substituting mechanical cutting tools with thermal welding processes, the difficulty of machining high alloy materials is eliminated, as welding can join and form these materials without the tool wear and complexity associated with machining them. This substitution resolves the contradiction between valve performance and manufacturing ease.
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 method simplifies the production process, reduces material usage and energy consumption, and allows for precise control over the technical properties of the protrusions, enabling efficient and flexible manufacturing of poppet valves with optimized performance.
Implementation Method 1
at least one protrusion is formed by at least one weld seam obtained by depositing material on said outer surface of said valve stem using a welding process
Implementation Method 2
providing said material in the form of a powder material, wherein said welding process comprises laser welding
Implementation Method 3
providing said material in the form of a powder material, wherein said welding process comprises laser welding
Data Source
Figure 1~3
Figure 4~5
AI summary
A poppet valve for a combustion engine is provided comprising a valve body with a valve stem and a valve head, wherein the valve comprises at least one protrusion of a predetermined shape located on the valve stem; wherein the at least one protrusion is formed by at least one weld seam obtained by depositing material on an outer surface of the valve stem with a welding process. Further, a method for producing a poppet valve having a protrusion on the valve stem is provided.