Valve Ball With Triangular Flow Opening

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing ball valves have limited flow regulation zones due to the need for precise angle rotation and suffer from mechanical and thermal issues with plastic inserts, leading to structural weaknesses and alignment problems, as well as costly and complex production processes.

Innovation Solution

A single-piece metal ball valve with a specifically shaped triangular opening in the through hole, manufactured using a controlled machining and punching process to ensure precise geometry and reduce burring, allowing for improved flow regulation and hermetic sealing without interference with seal materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a cylindrical through hole is used in the ball, then the structure is simple and easy to manufacture, but the flow regulation zone is limited and requires precise angle rotation

Engineering Contradiction:

Improvestructural simplicityVSAvoidflow regulation zone

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The through hole is segmented into multiple sections: a first through hole section with cylindrical shape and a second through hole section with specifically shaped opening. This segmentation allows different sections to serve different functions - the cylindrical section maintains structural simplicity while the specifically shaped opening enables wide flow regulation zone

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the through hole have different geometries tailored to specific functions. The first section maintains cylindrical symmetry for ease of manufacture, while the second section features a specifically shaped opening (triangular, rectangular, or other polygons) optimized for flow regulation characteristics

Inventive Principle:

Principle #3Local quality

2Ease of operation

If specifically shaped plastic inserts are used to improve flow regulation, then the flow characteristic can be equipercentual, but the mechanical resistance is lower and thermal expansion differs from the metal ball

Engineering Contradiction:

Improveflow characteristicVSAvoidmechanical resistance and thermal expansion compatibility

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The plastic insert is completely removed from the design. Instead of using a separate plastic component inserted into the metal ball, the specifically shaped opening is directly formed as an integral part of the metal ball body through punching or machining operations

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The function previously performed by the separate plastic insert is merged into the metal ball itself. The specifically shaped opening is created directly in the metal ball, combining the structural integrity of metal with the flow regulation functionality that previously required a plastic component

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If multiple metal parts are assembled to create a specifically shaped opening, then the mechanical strength is improved, but the production process becomes excessively long and costly requiring manual burr removal

Engineering Contradiction:

Improvemechanical strengthVSAvoidproduction process length and cost

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Multiple manufacturing operations are merged into a single punching or machining process. The specifically shaped opening is created in one step directly in the metal ball, eliminating the need for separate assembly operations and manual burr removal

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Manual mechanical operations (assembly and burr removal) are replaced with automated punching or machining processes. The punching operation creates the specifically shaped opening with precise geometry and minimal burring in an automated manner

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If the rim of the specifically shaped opening is on the same level as the seal surface, then the flow regulation is improved, but the seals are damaged and hermetic sealing is compromised

Engineering Contradiction:

Improveflow regulationVSAvoidhermetic sealing

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The potential harmful effect of the rim interfering with seals is prevented in advance by positioning the rim below the seal surface. This preliminary design consideration prevents seal damage before operation begins

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The ball surface is designed with different local geometries: the seal surface maintains a specific level for proper sealing contact, while the rim of the specifically shaped opening is positioned at a lower level to avoid interfering with the seal material during rotation

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8166994B2Ball for valves and production method

Publication Date: 2012.05.01 VIR VALVOIND ING RIZZIO

AI summary

A ball (1) for valves is described, comprising a substantially ball-shaped body (2), a hole (4, 5) bored in the body (2) for fluid flow passage between the entry and exit of the valve, and a slot (10) cut into the body (2) to house a pin for ball (1) rotation. The ball (1) is produced in a single element, and the hole (4, 5) terminates in a wall (6) in which a specifically shaped opening (12) is cut to regulate the amount of fluid flow between the entry and exit of the valve.