Valve Seat Locking via Plastic Deformation
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Solution Overview
Problem
The existing methods for manufacturing valves, particularly ball valves, are cost-intensive due to the need for machining and assembling multiple cast parts, which are often made from expensive alloys like brass, and involve time-consuming processes and welding, making them expensive and inefficient.
Innovation Solution
A valve design featuring a valve housing with a central part and connection ends, where the valve seat is resiliently fixed using a conical annular flange part that deforms to lock into the valve housing, minimizing cutting processes and using cheaper materials like carbon steel, and avoiding welding by using a plastically deformable tubular workpiece for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cast items are made of brass or copper-based alloy and machined individually, then the valve parts achieve high precision and reliability, but the manufacturing cost increases significantly and production time is extended
Solution Approach 1:
The valve housing is divided into a multipiece construction with separate parts that can be manufactured independently using less expensive materials and simpler processes, then assembled together to form the complete valve housing
Solution Approach 2:
The material parameter is changed from expensive brass/copper alloys to cheaper alternatives, and the manufacturing process parameter is changed from individual machining to assembly of pre-fabricated components
2Manufacturing precision
If cast items are individually machined, then the valve parts achieve desired geometry, but the manufacturing time and cost increase due to sequential processing
Solution Approach 1:
The valve housing parts are prepared in advance as separate components with pre-formed geometries, allowing parallel manufacturing of multiple parts before final assembly, thereby reducing the overall manufacturing cycle time
Solution Approach 2:
The valve housing is segmented into multiple parts that can be manufactured simultaneously through different processes and then assembled, avoiding the sequential machining of a single monolithic cast piece
3Reliability
If expensive alloys like brass are used for valve housing, then the valve achieves good machinability and durability, but the material cost increases significantly
Solution Approach 1:
The material parameter is changed from expensive brass/copper alloys to cheaper materials, reducing material cost while maintaining the required mechanical properties through appropriate material selection and design
Solution Approach 2:
Different materials can be used for different segments of the valve housing based on their specific functional requirements, allowing optimization of material cost while maintaining overall reliability
4Strength
If welding processes are used to assemble valve parts, then the valve achieves strong joints, but the production complexity and cost increase due to additional setup and processing steps
Solution Approach 1:
The welding process is replaced with a mechanical assembly method using threaded connections or interference fits, eliminating the need for welding equipment, setup, and post-weld processing while maintaining joint strength
Solution Approach 2:
The valve housing is designed as a multipiece construction that can be assembled through mechanical means such as threading or interference fits, avoiding the need for welding and simplifying the manufacturing process
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 solution allows for rapid and simple mounting of valve seats and bodies with reduced production costs, achieving high-quality and secure alignment while minimizing material costs and avoiding welding, enabling efficient production of valves for fluid regulation.
Implementation Method 1
a conical annular flange part (10) adapted for locking of the valve seat (8) in the valve housing (2) by deformation
Implementation Method 2
a resilient structural part where the spring action from the resilient structural part acts in a direction which is substantially in parallel with the flow direction of the valve
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The present invention concerns a valve and a method for producing a valve for regulating a fluid, the valve including a valve housing with a central part and with two connection ends, the connection ends extending away from the central part, thus indicating a flow direction for the fluid, wherein internally of the central part there is arranged a valve body including at least a shutoff part and a through-flow part. The valve seat is arranged in the valve housing and resiliently bearing against the valve body, the valve seat including a resilient structural part where the spring action from the resilient structural part acts in a direction which is substantially in parallel with the flow direction of the valve, and where the resilient structural part includes at least one annular flange part adapted for direct or indirect bearing on the valve body. The new feature of a valve according to the invention is that the resilient valve seat or seats include a fixing member for mechanical fixing of the valve seat in a valve housing, the fixing member including means, for example a flange part, fixed in a valve housing by plastic deformation of the valve housing and/or by plastic deformation of the means.