Shut-off Valve Top Ceramic Control Disc
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Solution Overview
Problem
Existing shut-off valves for fluid lines are prone to calcification, require multiple turns to shut off fluid flow, and are sluggish due to design limitations in plastic valve seats, which restrict the use of ceramic upper valve parts with passage windows and undercuts.
Innovation Solution
A shut-off valve upper part with a ceramic control and inlet disk, featuring a symmetrical hollow head piece with passage windows and an undercut for a sealing ring, is designed for easy quarter-turn operation by integrating a metal threaded sleeve with a cylindrical recess in a plastic valve seat, preventing calcification and ensuring fluid passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional shut-off valve upper part is used, then it can be manufactured with plastic injection molding, but it is susceptible to calcification and deposits
Solution Approach 1:
The invention uses a composite structure combining plastic (for the valve seat body) and ceramic (for the upper valve part including control disk and inlet disk). The ceramic material is specifically chosen for its resistance to calcification and deposits, while the plastic provides ease of manufacturing and sealing. This composite approach allows the upper valve part to be made of ceramic material that is resistant to calcification, while the plastic valve seat maintains manufacturing simplicity.
2Ease of operation
If a conventional shut-off valve design is used, then the valve body can be pressed against the valve disk, but several turns of the spindle are required to shut off the fluid line
Solution Approach 1:
The invention segments the flow path by introducing passage windows in the head piece that are radially offset from the central axis. This segmentation allows fluid to flow through multiple paths simultaneously, enabling quarter-turn operation. The control disk with its specific geometry and the radially offset passage windows work together to achieve rapid shut-off in just a quarter turn of the spindle, dramatically reducing the time and turns required compared to conventional designs.
3Ease of operation
If an undercut is provided on the valve seat for quarter-turn operation, then the valve can be operated easily, but the mandrel cannot be pulled out after injection molding
Solution Approach 1:
The invention applies local quality by providing the undercut feature only in specific regions where it is functionally necessary for quarter-turn operation, while maintaining a smooth cylindrical surface in the region where the mandrel is extracted. The passage windows are positioned radially offset from the central axis, allowing the undercut to be located in areas that do not interfere with mandrel removal. This localized application of the undercut geometry enables both easy quarter-turn operation and successful mandrel extraction during manufacturing.
4Productivity
If a ceramic upper valve part with passage windows is used, then quarter-turn shut-off is achieved, but the threaded sleeve or cylindrical passage closes the passage window
Solution Approach 1:
The invention resolves the passage window closure issue by changing the dimensional arrangement of the flow paths. The passage windows are positioned radially offset from the central axis of the valve, creating a staggered, multi-dimensional flow pattern. This radial offset arrangement ensures that when the control disk rotates for shut-off, the passage windows remain aligned with the flow paths and are not blocked by the threaded sleeve or cylindrical passage. The head piece geometry is specifically designed to maintain open flow paths throughout the quarter-turn rotation.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
Shut-off valve top for screwing into the plastic valve seat of a fluid line, with a head piece which is centrally penetrated by a rotatably mounted spindle, over which a ceramic control disc can be rotated relative to a stationary valve seat disc for controlling the fluid flow, wherein the head piece has a sleeve-shaped part in which at least one passage window is arranged, which can be flowed through by a fluid when the valve is in the open position, and wherein a threaded piece having an external thread is arranged for screwing into an internal thread of the valve seat, wherein the threaded piece (13) forms a shoulder (132) above the at least one passage window (11) relative to the sleeve-like part (10), such that a circumferential radial gap is formed between the inner diameter of the internal thread of the valve seat (61) and the sleeve-like part (10) having the at least one passage window (11).The invention further relates to a conduit section (6) with a plastic valve seat (61) into which a metallic threaded sleeve (7) having an internal thread is injected, wherein a shut-off valve according to one of the preceding claims is inserted into the valve seat (61), the threaded part (13) of which is screwed into the internal thread (71) of the threaded sleeve (7) such that a gap for fluid passage is formed between a region of the internal thread (71) and the sleeve-like part (10) of the head (1) of the shut-off valve.