Integral Plastic Ball Valve for Fluid Transmission And Manufacturing Process

• US 20150308576A1
• Filed: 04/26/2014
• Published: 10/29/2015
• Est. Priority Date: 04/26/2014
• Status: Abandoned Application

• Current Assignee: Doug Yelkin, Wei Hua Li
• Original Assignee: Doug Yelkin, Wei Hua Li
• Inventors: Yelkin, Doug, Li, Wei Hua
• Application Number:
  US14/262,726
• Publication Number:
  US 20150308576A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 2045/14131 using positioning or centering means forming part of the insert
• CPC Class Codes: B29C 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/261 having tubular mould cavities
• CPC Class Codes: F16K 27/067 with spherical plugs
• CPC Class Codes: F16K 5/0642 the spherical plug being insertable from one and only one side of the housing
• CPC Class Codes: F16K 5/0689 between housing and plug

Abstract

The inventive concept relates to a completely integral ball valve manufactured by an injection fusing 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 fusion 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 fusing molding.

Claims

1. An integral ball valve, comprised of plastic or similar material, utilized in controlling the transmission of fluids through various sizes of pipelines, comprising

(a) a spherical enclosure having a generally cylindrical structure and further having a top surface with a central circular aperture, a circular inner face, a bottom surface, an outer vertical face, a left leakage seal ring, and a barrel opening with a ring-shaped, vertical outer face;

(b) left and a right leakage seal rings, each seal ring having a first diameter and a raised lip extending continuously about the circumference of one side of each leakage seal ring;

(c) a rod-shaped valve stem having a plurality of circumferentially-circumscribed grooves into which are installed gasket O-rings, a top-most notch, and a bottommost shaft having a polygonal cross-section;

(d) a valve handle having an interior tubular-shaped cavity corresponding to the outer dimensions of said valve stem;

(e) a valve ball consisting of i) a sphere of outer diameter corresponding to the barrel opening of said spherical enclosure, ii) a through-hole of diameter corresponding to the first diameter of said leakage seal rings, said through-hole forming a left ball outlet and a right ball outlet, and iii) a topmost polygonal socket with a cross-section corresponding to the cross-sectional dimensions of the shaft of said valve stem;

(f) a spherical enclosure cap assembly consisting of a cap opening corresponding to the right ball outlet of said valve ball, a circumferential flange, a sealing gasket placed about the outer circumference of said flange, a right leakage seal ring, a cap first face, and a cap second face, said cap first face being placed in abutment to the outer vertical face of the spherical enclosure and thereby forming a valve core having a left main port and a right main port;

(g) a left flow pipe and a right flow pipe; and

(h) a valve body housing integral to, and encompassing the outer surfaces of said valve core, further encompassing said left main port and said right main port, simultaneously encompassing a segment of an end of the left flow pipe and an end of the right flow pipe, respectively;

wherein

said valve ball occupies a fitted space within the barrel opening of said spherical enclosure, with placement of left and right leakage seal rings vertically on both sides of said valve ball and the through-hole lined up axially with the outer face of said spherical enclosure, the enclosure cap assembly is fitted onto the outer face of said spherical enclosure, the left and right flow pipes integral to, and projecting coaxially from the left and right sides of the valve body housing, the valve stem being securely attached to the valve ball polygonal socket such that the valve stem polygonal shaft is fitted into the polygonal socket of said valve ball, the valve body housing encompasses the valve core, the valve handle is fastened onto the uppermost part of the valve stem, and further, the left flow pipe and the right flow pipe extend coaxially and symmetrically from the left main port and the right main port of the valve body housing respectively.

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 process of injection fusion molding for the manufacture of an integral ball valve composed of plastic or similar substance, utilized in controlling the transmission of fluids through various sizes of pipelines, comprising the following steps:

(a) providing a spherical enclosure having a generally cylindrical structure and further having a a top surface with a central circular aperture, a circular wall, a bottom surface, a barrel opening, and a ring-shaped vertically oriented outer face;

(b) providing a left and a right leakage seal ring, each seal ring having a first diameter and a lip extending continuously about the circumference of one side of each leakage seal ring;

(c) placing the left leakage seal ring into the spherical enclosure so as to abut the inner face;

(d) providing a valve ball consisting of a sphere of outer diameter corresponding to the barrel opening of said spherical enclosure, a through-hole of diameter corresponding to the first diameter of said leakage seal rings, said through-hole forming a left ball outlet and a right ball outlet, and a topmost polygonal socket;

(e) placing said valve ball into the spherical enclosure such that the through-hole is co-axial with the circular wall, and such that the socket of said valve ball is oriented vertically upward proximate said central aperture;

(f) providing a rod-shaped valve stem having a plurality of circumferentially-circumscribed grooves into each groove which is fitted a gasket O-ring, a top-most notch, and a bottommost shaft having a polygonal cross-section corresponding to the cross-sectional dimensions of the socket of the valve ball;

(g) placing the valve stem downward through the central aperture such that the valve stem shaft is fitted into the valve ball socket;

(h) providing a spherical enclosure cap having a first inner face of a certain diameter, a second inner face of a smaller diameter than the first inner face, a cap opening corresponding to the right ball outlet of said valve ball, and a circumferential flange;

(i) fabricating a sub-assembly comprising a right leakage seal ring placed abutting the second face of said spherical enclosure cap and a sealing gasket placed snugly around the outer diameter of the flange of said spherical enclosure cap;

(j) placing the spherical enclosure cap sub-assembly flush against the outer face of said spherical enclosure such that the flange of the spherical enclosure cap fits snugly within the barrel opening of the spherical enclosure, thereby forming a valve core;

(k) co-axially placing a left mold rod and a right mold rod into the left ball outlet and the right ball outlet, respectively;

(l) providing an injection mold having a first section and a second section, each section 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 housing encompassing said valve core, and further a left flow pipe and a right flow pipe;

(m) placing the valve core and mold rods into the first injection mold half, placing and securing the second mold half onto the first mold half, placing the combined mold in connection with an mold injection machine and initiating the flow of molten substance into the mold;

(n) allowing an adequate cooling time for the mold, and afterwards, removing an assembly comprising the integral valve housing and the left and right outlet/inlet pipes; and

(o) assembling the valve handle onto the valve stem of said valve core, thereby completing said ball valve.