Integral Plastic Ball Valve For Fluid Transmission And Manufacturing Process

Abstract

The inventive concept discloses a completely integral ball valve manufactured by an injection molding process. The device comprises a valve core, a valve housing, a valve control handle, and inlet/outlet flow pipes, all forming an integral structure. The valve core is the primary component of the ball valve, and is comprised of a spherical enclosure, a valve ball, left and right leakage seal rings, a spherical enclosure cap, a valve stem affixed to the valve ball, and a valve handle. The valve core, valve housing, and left and right intake/outflow pipes are integrally assembled by injection molding. The injection molding process gives the ball valve higher flexion strength and greater durability as compared to the typical sweat soldering process. Precisely dimensioned mold sections ensure the accuracy of dimensions, fittings, and tolerances of the ball valve components during the injection molding. Primary materials used are polypropylene and high-density polyethylene

Claims

1. An integral plastic ball valve, said ball valve comprising: (a) a spherical enclosure having a generally cylindrical structure and further having a collar with a circular through-aperture, a circular inner face, a peripheral surface, and a barrel opening, said barrel opening having an annular-shaped outer face, said outer face being oriented parallel to the axis of the circular aperture; (b) identical left and a right leakage seal rings, each seal ring having a continuous circumferential lip on one side of the ring; (c) a rod-shaped valve stem having a notch on the first end of said stem, a plurality of installed gasket O-rings, and a polygonal cross-section on the second end of said valve stem; (d) a valve handle having a cavity corresponding to the notch of said valve stem; (e) a valve ball comprising i) a sphere; ii) a through-hole corresponding to an axis of the valve ball, said through-hole thereby forming a left ball outlet and a right ball outlet, and iii) a topmost polygonal socket with a cross-section corresponding to the second end of said valve stem; (f) an annular-shaped spherical enclosure cap comprising a cap opening corresponding to the right ball outlet; a circumferential flange constructed about the cap opening; an annular-shaped cap first face on the first side of the spherical enclosure cap, and exterior to said flange; a cap second face oriented about the inner perimeter of said flange and having an inner diameter corresponding to the right ball outlet; and said cap first face having an inner and outer diameter corresponding to the outer face of said barrel opening (g) a sealing gasket having an outer diameter corresponding to the inner diameter of said circumferential flange; (h) a left flow pipe integral to and coaxial with the left ball outlet and a right flow pipe integral to and coaxial with the right ball outlet; and (i) a valve body housing.

2. An integral ball valve as in claim 1 wherein the valve stem is constructed of steel, the spherical enclosure, valve ball, and spherical enclosure cap are constructed of polypropylene, and the valve housing is constructed of polyethylene.

3. An integral ball valve as in claim 1, wherein the valve stem is constructed of polyformaldehyde, the spherical enclosure, valve ball, and spherical enclosure cap are constructed of polypropylene, and the valve housing is constructed of polyethylene.

4. An integral ball valve as in claim 1, wherein the valve stem is constructed of aldehyde acetal, the spherical enclosure, valve ball, and spherical enclosure cap are constructed of polypropylene, and the valve housing is constructed of polyethylene.

5. A method for the manufacture, by injection molding, of an integral ball valve, the ball valve primarily consisting of polyformaldehyde, polypropylene, and polyethylene materials, the method comprising the following sequential steps; (a) providing a spherical enclosure comprising a polypropylene cylindrical structure and further having a collar with a circular through-aperture, a circular inner face, a peripheral surface, and a barrel opening having a ring-shaped outer face, said outer face being oriented parallel to the axis of the circular aperture; (b) providing identical left and right leakage seal rings, each seal ring having a first side with dimensions corresponding to the inner face of said spherical enclosure and a circumferential lip on the second side of each ring; (c) placing the first side of said left leakage seal ring into the spherical enclosure so as to abut the inner face; (d) providing a rod-shaped valve stem having a notch on the first end of the valve stem and a polygonal cross-section comprising the second end of the valve stem; (e) providing a valve handle having an internal cavity corresponding to the notch of the valve stem; (f) providing a valve ball comprising a polypropylene sphere with outer diameter corresponding to the barrel opening of the spherical enclosure, a through-hole of diameter corresponding to the inner diameter of said leakage seal rings, said through-hole forming a left ball outlet and a right ball outlet; and a polygonal socket oriented orthogonal to the through-hole; (g) placing said valve ball into the spherical enclosure such that the through-hole is co-axial with the outer face of the barrel opening and such that the polygonal socket of said valve ball is oriented co-axially with the central aperture; (h) placing the valve stem downward through the central aperture such that the valve stem shaft is fitted into the valve ball socket; (i) providing an annular-shaped spherical enclosure cap comprising polypropylene, with inner diameter equivalent to the ball outlets of said valve ball, a circumferential flange about the circumference of the first side of the spherical enclosure cap, an annular-shaped cap first face on the first side of the spherical enclosure and oriented about the outer perimeter of the circumferential flange, an annular-shaped cap second face oriented about the inner perimeter of the circumferential flange and having an inner diameter corresponding to the right ball outlet; said cap first face corresponding to the outer face of said barrel opening; (j) placing the first side of said right leakage seal ring in abutment to the second face of said spherical enclosure cap and placing the sealing gasket around the outer diameter of the flange of the spherical enclosure cap; (k) placing the cap first face flush against the outer face of the spherical enclosure such that the flange of the spherical enclosure cap fits within the barrel opening of the spherical enclosure; (l) co-axially placing a left mold rod and a right mold rod into the left ball outlet and the right ball outlet, respectively; (m) providing an injection mold having a first mold cavity and a second mold cavity, each cavity comprising a concave profile corresponding to the general longitudinal shape of the valve core and the previously-inserted left mold rod and right mold rod, thereby forming a valve body housing encompassing said valve core, and further a left flow pipe and a right flow pipe; (n) placing the valve core and mold rods into the first injection mold cavity, placing and securing the second mold cavity onto the first mold cavity, placing the combined mold cavities in connection with a mold injection machine and initiating the flow of molten substance into the combined mold cavities; (o) alter cooling of the mold, removing an assembly comprising the integral valve body housing and the left and right outlet/inlet pipes; and (p) fastening the valve handle onto the valve stem of the valve core.

6. An improved method of manufacturing an integral plastic ball valve of the type having a spherical ball with a cylindrical through-hole, a left ball outlet, a right ball outlet, and a polygonal socket in the outer surface of said ball, the improvement comprising: (a) assembling a valve core consisting of a spherical enclosure, left and right leakage seal rings, a sealing gasket, the valve ball, a valve stem, and a spherical enclosure cap; (b) co-axially placing a left mold rod and a right mold rod into the left ball outlet and the right ball outlet, respectively; (c) providing an injection mold having a first mold cavity and a second mold cavity, each cavity comprising a concave profile corresponding to the shape of the valve core and mold rods, thereby forming a valve body housing encompassing said valve core; (d) placing the valve core and mold rods into the combined mold cavities in correspondence with a mold injection machine and initiating the pressurized flow of molten substance into the combined mold cavities; and (e) allowing an adequate cooling time for the mold, and afterwards, removing the integral valve body housing and the left and right outlet/inlet pipes.

7. An integral ball valve as in claim 6 wherein the valve stem is constructed of steel, the spherical enclosure, valve ball, and spherical enclosure cap are constructed of polypropylene, and the valve housing is constructed of polyethylene.

8. An integral ball valve as in claim 6, wherein the valve stem is constructed of polyformaldehyde, the spherical enclosure, valve ball, and spherical enclosure cap are constructed of polypropylene, and the valve housing is constructed of polyethylene.

9. An integral ball valve as in claim 6, wherein the valve stem is constructed of aldehyde acetal, the spherical enclosure, valve ball, and spherical enclosure cap are constructed of polypropylene, and the valve housing is constructed of polyethylene.

10. A method for the manufacture, by injection molding, of an integral ball valve, the ball valve materials primarily consisting of polyformaldehyde, polypropylene, and polyethylene, the method comprising the following sequential steps: (a) providing a spherical enclosure comprising a polypropylene cylindrical structure having a barrel opening manifesting a circular outer face, and a collar with a circular through-aperture, (b) providing an annular-shaped spherical enclosure cap comprising polypropylene, further having a circular flange of an outer circumference corresponding to the outer surface of the barrel opening, whereby the spherical enclosure cap fits onto the outer face of the barrel opening; (c) providing a valve ball comprising a polypropylene sphere with outer diameter corresponding to the barrel opening of the spherical enclosure, a through-hole forming co-axial left ball outlet and a right ball outlet; and a polygonal socket oriented orthogonally to the axis of the through-hole; (d) providing identical left and right leakage seal rings, each seal ring having an annular first side and a second side with a circumferential lip, whereby each circumferential lip corresponds to the outer surface of the valve ball; (e) providing a rod-shaped valve stem having a notch on the first end of the valve stem and a polygonal cross-section equivalent to that of the ball socket comprising the second end; (f) providing a valve handle having an internal cavity corresponding to the notch of the valve stem; (g) forming a valve core by means of placing the valve stem downward through the collar of the spherical enclosure so as to fit into the valve ball socket, placing a circular gasket in abutment with the cap first face, placing the assembled valve ball and leakage seal rings into the barrel opening of the spherical enclosure, whereupon placement of the spherical enclosure cap is made onto the outer face of the spherical enclosure, and co-axially placing a left mold rod and a right mold rod into the left ball outlet and the right ball outlet, respectively; (h) providing an injection mold for sealed accommodation of the valve core and left and right mold rods and initiating, the flow of molten polyethylene into the combined mold cavities; (i) upon cooling of the mold, removing of the end product comprises an integral valve body housing containing the valve core; and (j) fastening the valve handle onto the valve stem of the valve core.

11. The method as in claim 10, wherein the valve stem is constructed of steel.

12. The method as in claim 10, wherein the valve stem is constructed of polyformaldehyde.

13. The method as in claim 10, wherein the valve stem is constructed of aldehyde acetal.

Description

BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS

[0037] FIG. 1 presents the completely assembled ball valve 1 and its integral inlet and/or outlet pipes 37, 38.

[0038] FIG. 2 depicts a perspective view of the spherical enclosure 4, which forms the foundation for assembly of components to manufacture the ball valve 1 by injection molding.

[0039] FIG. 3 presents a cross-sectional view of the spherical enclosure 4, as seen from the section line, 2-2; also shown is the left leakage seal ring 10 just prior to its placement against the inner face 33 of the spherical enclosure 4.

[0040] FIG. 4 shows a cross-sectional view of the left leakage seal ring 10 having been placed in abutment to the inner face 33 of the spherical enclosure 4.

[0041] FIG. 5 shows the valve stem 20 of the ball valve 1 along with circumferential grooves 23.

[0042] FIG. 6 illustrates the valve stem 20 having been fitted with three gasket O-rings 25 at critical points along the length of the valve stem 20.

[0043] FIG. 7 depicts the valve ball 5 just prior to its insertion into the spherical enclosure 4.

[0044] FIG. 8 illustrates the valve ball 5 inserted into the spherical enclosure 4 and in abutment with the left leakage seal ring 10.

[0045] FIG. 9 is a sectional view of the valve stem 20 in alignment with an aperture 13 atop the spherical enclosure 4 and the ball socket 8.

[0046] FIG. 10 is a sub-assembly comprising the spherical enclosure 4, valve ball 5, and the valve stem 20.

[0047] FIG. 11 illustrates the valve ball 5 and the ball polygonal socket 8 in the top surface of the valve ball 5.

[0048] FIG. 12 depicts a sectional view of the pending assembly of the spherical enclosure cap 15, a sealing gasket 14, and the right leakage seal ring 11.

[0049] FIG. 13 is a stand-alone view of the sealing gasket 14 shown in FIG. 12.

[0050] FIG. 14 is a sub-assembly consisting of the spherical enclosure cap 15, the sealing gasket 14, and the right leakage seal ring 11.

[0051] FIG. 15 presents the pending joining of the enclosure cap 15 sub-assembly with the spherical enclosure 4 containing the valve ball 5 and valve stem 20.

[0052] FIG. 16 depicts the assembled components of what is termed the valve core 2, as shown.

[0053] FIG. 17 shows the outlined pattern of the corresponding mold sections 58, 59 used in the final injection molding process and further, the pending installation of the valve handle 21 onto the valve stem 20 and the valve body housing 50.

DETAILED DESCRIPTION OF THE INVENTIVE CONCEPT

[0054] The inventive concept disclosed herein features a ball valve that is manufactured by a method comprising injection molding. An understanding of the inventive concept is best conveyed by reference to the accompanying drawing figures, of which there are seventeen in number. A step-by-step tracking of the process of manufacturing, the ball valve 1 provides a thorough explanation of the particular injection molding process. Starting with FIG. 1, there is presented a completely assembled ball valve 1, with the valve body housing 50, and integral inlet and/or outlet pipes 37, 38, the outlet pipes 37, 38 having been fabricated during the injection molding process. Also shown is the ball valve 1 control handle 21 for setting the direction and volume of the flow of internally transmitted fluids and for shutting off the fluid flow.

[0055] The primary component, of the ball valve 1 assembly is the spherical enclosure 4, which is shown in perspective in FIG. 2. The spherical enclosure 4 is essentially a cylindrically-shaped unit having a top surface 4(a) having a centralized circular aperture 13, a bottom surface 4(b), a barrel opening 35, a ring-shaped vertically oriented outer face 32. The spherical enclosure 4 forms the foundation for assembly of the necessary components of the ball valve 1. Upon complete assembly of the components, what is termed a valve core 2 (shown in FIG. 16) is then placed into appropriate mold forms 58, 59 (shown in FIG. 17) to initiate the injection molding process, as will be shown in the following discussions.

[0056] Referring to FIG. 3, there is presented a cross-sectional view of the spherical enclosure 4, as seen from section line, 2-2 of FIG. 2. To the right of the spherical enclosure 4 is shown a left leakage seal ring 10, which is essentially a gasket having a continuous circumferential lip 12 on the inner side of the left leakage seal ring 10. A right leakage seal ring 11 (not shown) is also made in an identical manner. In the pre-injection process, both leakage seal rings 10, 11 will be inserted in appropriate locations in the spherical enclosure 4. Further shown in FIG. 3 is a lip 12 which is contoured to fit snugly against the valve ball 5 upon complete assembly of the ball valve 1.

[0057] Also shown in FIG. 3 is the barrel opening 35 and the outer bottom 36 of the spherical enclosure 4. A flat circular outer face 32 is constructed of dimensions which accommodate the snug fit of a gasket 14 and a spherical enclosure cap 15 (more clearly shown in FIG. 15 and FIG. 16). A circular inner face 33 is structured so as to accept an abutting fit of the surface of the left leakage seal ring 10 during assembly. A left main port 51 is depicted, which allows the fitting of a left flow pipe 37, which in turn facilitates the flow of a fluid into or out of the ball valve 1.

[0058] FIG. 4 shows the resulting sub-assembly after insertion of the left leakage seal ring 10 in direct abutment with the ring-shaped inner face 33 of the spherical enclosure 4.

[0059] FIG. 5 illustrates a valve stem 20 which provides a mechanical union between the valve ball 5 (not shown) and a control valve handle 21 (also, not shown) which union thereby provides the means for manually controlling flow of a fluid through the fully assembled ball valve 1. The valve stem 20 further features three circumferentially-machined grooves 23 and a stem polygonal shaft 24, the shaft having a cross-section corresponding to the contours of a ball polygonal socket 8 (shown in FIG. 11). A stem notch 26 accommodates the attachment of a valve handle 21 as shown in FIG. 17.

[0060] FIG. 6 depicts the placement of an elastomeric gasket O-ring 25 into each of the three grooves 23 of the valve stent 20. The gasket O-rings 25 play a critical part in preventing the leakage of fluid around the exterior surface of the valve stem 20.

[0061] FIG. 7 shows another rendering of a cross-sectional view of the spherical enclosure 4 sub-assembly, as seen from section line 2-2. To the right of the spherical enclosure 4 in FIG. 7 is shown the valve ball 5 which is a spherical structure having a through-hole oriented left-to-right, the through-hole defining a left ball channel 6 and a right ball channel 7. On the top surface of the valve ball 5 is shown, by hidden lines, the polygonal-shaped socket 8 which is comprised of dimensions corresponding to the polygonal cross-section of the polygonal shaft 24 of the valve stem 20. At this point in time in the manufacturing process, the valve ball 5 is placed into the barrel opening 35 of the spherical enclosure 4, as is illustrated in FIG. 8, immediately following.

[0062] FIG. 8 demonstrates that the valve ball 5 is placed in abutment to the left leakage seal ring 10. It is also noted that the left ball channel 6 is co-axial with, and of a diameter corresponding to, the left main port 51 of the spherical enclosure 4. The contour of the left side of the valve ball 5 fits the contour of the circumferential lip 12 of the left leakage seal ring 10.

[0063] FIG. 9 presents the next sequential step in the manufacturing process, which depicts the pending insertion of the valve stem 20 into the sub-assembly comprising the spherical enclosure 4 and the valve ball 5. For further clarification, FIG. 11 is a perspective rendering of the valve ball 5, showing the right ball channel 7 and the ball polygonal socket 8. FIG. 10 illustrates the next stage of the sub-assembly process, comprising the spherical enclosure 4, the valve ball 5, and the valve stem 20. FIG. 10 also demonstrates the manner in which the valve shaft 24 fits snugly into the ball polygonal socket 8.

[0064] Proceeding with the assembly process. FIG. 12 shows individual components being, a cross-sectional view of a spherical enclosure cap 15, a sealing gasket 14, and further, a cross-sectional view of the right leakage seal ring 11. The spherical enclosure cap 15 comprises a cap first face 17, a cap circular opening 18, (which will ultimately form the right main port 52 of the ball valve 1), a cap second face 19, and a circular flange 16. FIG. 13 presents a perspective view of the sealing gasket 14, which will ultimately abut the outer face 32 of the spherical enclosure 4.

[0065] FIG. 12 demonstrates that the inner diameter of the sealing gasket 14 corresponds to the outer circumference of the flange 16, and that the flat face of the gasket 14 corresponds to the cap first face 17. The manufacturing process continues by placement of the sealing gasket 14 against the cap first face 17, to simultaneously fit about the outer circumference of the circular flange 16. The right leakage seal ring 11 is then placed so as to abut the cap second facer 19 and contemporaneously fit co-axially about the cap opening 18. The interior wall cap opening 18 corresponds in dimensions, to the right ball outlet 7 and also will ultimately form the right main port 52 of the ball valve 1. FIG. 14 then depicts the completed sub-assembly of the spherical enclosure cap 15 with the components shown in FIG. 12 and FIG. 13.

[0066] FIG. 15 displays the procedure for placing the completed sub-assembly of the spherical enclosure cap 15 so as to abut the outer face 32 of the spherical enclosure 4. FIG. 16 illustrates the final assembly of the essential valve core 2 of the ball valve 1. The valve core 2 assembly culminates in the through-hole of the valve ball 5 being co-axial with the left main port 51, the cap opening 18, and the right main port 52 of the valve core 2.

[0067] FIG. 17 represents the final phases of the injection molding process. In a separate operation in the sequence of the process, a left mold rod 56 having an outer circular diameter corresponding to the inner diameter of the left main port 51 is inserted, co-axially, into the left main port 51 of the valve core 2. A right mold rod 57 having an outer circular diameter corresponding to the inner diameter of the right main port 52 is inserted, co-axially, into the right main port 52 of the valve core 2. The valve core 2 and the conjoined valve stem 20 are then precisely placed into a custom-contoured first mold cavity 58. Also shown is the outline of a corresponding second mold cavity 59 having contours and dimensions exactly corresponding to the first mold cavity 58.

[0068] The first mold cavity 58 comprises dimensions so as to provide spacing for the formation of a left flow pipe 37 encircling the left mold rod 56 as the selected molten material is injected into the clamped mold cavities, 58, 59. Similarly, the first mold cavity 58 comprises dimensions so as to provide spacing for the formation of a right flow pipe 38 encircling the right mold rod 57. In this manner both flow pipes 37, 38 become integral to the ball valve 1 resulting from the injection of the selected molten material during the molding process.

[0069] The first mold cavity 58, as does the second mold cavity 59, further comprises contours to form a valve body housing 50. The valve body housing 50, in its final form, encloses the entire valve core 2. During the injection molding process, the body housing 50 thereupon becomes integral to the left and right flow pipes 37, 38. Simultaneously, the valve body housing 50 becomes integral to the valve core 2 and valve stem 20. Upon careful placement of the valve core 2 and the conjoined valve stem 20 into the first mold cavity 58, both mold cavities 58, 59 will be overlaid and clamped together in preparation for injection of a selected molten substance. After cooling and permanent setting of the molten material the two mold cavities 58, 59, are separated and the left and right mold rods 57 are removed. The valve core 2, complete with the left and right flow pipes 37, 38, is then removed from the first mold cavity 58 and the handle cavity 22 of the valve handle 21 is fitted onto the valve stem 20. The final ball valve assembly 1 is then trimmed and ready for service.

[0070] A major technical solution advanced by the present inventive concept is a process for manufacturing an integral plastic ball valve used for controlling the transmission of fluids through various sized pipelines. The term plastic is used in this disclosure to generally encompass a range of materials suitable for the components of the inventive concept, including, but not limited to polypropylene, polyethylene, and others. In preferred embodiments, the valve stem 20 is constructed of steel, polyformaldehyde, or aldehyde acetal; the spherical enclosure 4, valve ball 5, and spherical enclosure cap 15 are constructed of polypropylene. The valve housing 50, in the preferred embodiment, comprises polyethylene.

[0071] The preferred embodiments of the present invention, having been disclosed and described above in detail, it is understood that various changes and modifications can be made by one having skill in the art involved with this field of manufacture. Therefore, all technical solutions and/or variations arrived at by those skilled in the art, with respect to the concept of the present inventive concept, whether based on the prior art, logical analysis, or inferences, fall within the protective scope as denned by the claims herein.