Welded Check Valve Assembly With Retained Internal Components
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Solution Overview
Problem
Check valves assembled with threaded connections face high manufacturing costs and potential media leakage due to temperature variations, especially in high-purity fluid control applications like semiconductor manufacturing.
Innovation Solution
Welding polymeric components together to create check valves, using thermal welding techniques while incorporating retaining features to keep components away from the weld site, thereby reducing particle generation and improving sealing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If threaded connections are used to assemble check valve components, then the manufacturing process is simpler and components can be disassembled, but manufacturing costs increase and temperature variations cause media leakage
Solution Approach 1:
The patent replaces the mechanical threaded connection system with a welding system. The check valve body and end caps are joined through welding instead of threading, eliminating the complexity of threaded assemblies while providing superior sealing that is not affected by temperature variations.
Solution Approach 2:
The patent changes the joining method from mechanical (threaded) to thermal (welded). This parameter change in the connection method eliminates the clearance and potential leakage paths inherent in threaded connections, providing a more reliable seal that maintains integrity across temperature variations.
2Ease of repair
If threaded connections are used to assemble check valve components, then disassembly is possible, but manufacturing costs increase
Solution Approach 1:
The patent replaces the mechanical threaded connection system with a welding system. The check valve body and end caps are joined through welding instead of threading, eliminating the complexity of threaded assemblies while providing superior sealing that is not affected by temperature variations.
3Productivity
If components are positioned close to the weld site during thermal welding, then the welding process is more efficient, but the components are damaged or improperly bonded
Solution Approach 1:
The patent segments the check valve into modular components (body, end caps, internal assembly) that can be assembled and positioned independently. Retaining features within the body create distinct zones that hold components away from the weld area, allowing efficient welding without compromising component integrity.
Solution Approach 2:
The patent introduces retaining features as intermediary structures between the components and the weld site. These features act as mediators that maintain proper spacing, preventing direct exposure of components to weld heat while preserving the efficiency of the welding 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
Simplifies the manufacturing process, enhances the quality of the seal, and reduces potential leakage, offering improved performance in high-purity fluid control applications by eliminating threaded connections and protecting components from damage during the welding process.
Implementation Method 1
The first outer piece and the second outer piece are joined together by a weld. The check valve may be welded using thermal welding techniques.
Implementation Method 2
Holding the check valve components away from the weld site can prevent the welding process from damaging or improperly bonding melt processable components of the check valve.
Data Source
AI summary
Welded check valves include a poppet assembly, a spring, and a disc that contacts the spring. The disc may be held at a position away from a weld when forming the welded check valve. Embodiments may include retention features configured to allow one or more of the poppet assembly and disc to pass the retention features in an assembly orientation, and to retain those elements when they are in an operational orientation. Methods include inserting the poppet assembly, contacting the poppet assembly with a spring, inserting a disc, retaining the disc away from a weld side, and welding the check valve together. The poppet assembly and/or disc may pass one or more retaining features when inserted, and be retained by the retaining features when the check valve is operated. The weld may be a thermal weld.