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US20120216404A1 - Manufacturing method of a valve - Google Patents

Manufacturing method of a valve Download PDF

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Publication number
US20120216404A1
US20120216404A1 US13/389,543 US201013389543A US2012216404A1 US 20120216404 A1 US20120216404 A1 US 20120216404A1 US 201013389543 A US201013389543 A US 201013389543A US 2012216404 A1 US2012216404 A1 US 2012216404A1
Authority
US
United States
Prior art keywords
housing
valve
welding
manufacturing
inner liner
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/389,543
Inventor
Jesper Hoejland Hoeyer
Hans Kurt Petersen
Erik Thomas Bonde
Ole Mortensen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Danfoss AS
Original Assignee
Danfoss AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Danfoss AS filed Critical Danfoss AS
Assigned to DANFOSS A/S reassignment DANFOSS A/S ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BONDE, ERIK THOMAS, HOEJLAND HOEYER, JESPER, MORTENSEN, OLE, PETERSEN, HANS KURT
Publication of US20120216404A1 publication Critical patent/US20120216404A1/en
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K27/00—Construction of housing; Use of materials therefor
    • F16K27/10—Welded housings
    • F16K27/102—Welded housings for lift-valves
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49405—Valve or choke making
    • Y10T29/49426—Valve or choke making including metal shaping and diverse operation

Definitions

  • the present invention relates to a method to manufacture a valve using metal injection moulding and welding the valve housing to the upper part of the valve without damaging the inner cavity of the valve housing.
  • a valve housing is usually manufactured by forging or turning or a combination of those. In a traditional forging process it is difficult to manufacture details inside the valve and often further adaption of the housing is necessary after the forging giving extra work and also expensive material is wasted. When manufacturing a valve typically soldering or screw joints are used to assemble the housing to the other parts of the valve.
  • Metal injection moulding is a manufacturing method that at relatively low costs allows manufacturing parts effectively and precise.
  • metal powder is mixed with a polymeric binder.
  • the MIM material is heated and then injected in a mould.
  • the part obtained after the injection moulding is slightly larger in size than the final part.
  • the part then goes through a debinding process where about 90% of the polymeric binder is removed.
  • the part is sintered to remove the majority of the remaining polymeric binder and the sintering also makes the metal powder to fuse together creating a solid part.
  • the sintering also makes the part shrink to its final size.
  • a problem by MIM is that the walls of the part have to be relatively thin to allow the debinding process and the sintering to remove almost all the polymeric binder. Therefore making parts to be welded by using the MIM process is difficult because thin walls easy deforms during welding.
  • the invention provides a method for manufacturing a valve, the valve comprising a housing and an upper part, the housing is manufactured by metal injection moulding, the housing comprises an welding cap, and the upper part is welded to the welding cap.
  • metal injection moulding makes it possible to manufacture the housing cheap using a minimum of material since the waste of material is very limited.
  • the thickness of the walls must be limited to allow for the debinding process and the sintering process to remove almost all of the polymeric binder. If the walls are too thick it is difficult to remove almost all of the polymeric binder. Therefore the walls must be relatively thin compared with a housing manufactured in a traditional way. Thin walls give a problem when the housing is welded to the upper part as the welding can deform the housing making it difficult for the inner parts to move freely. Therefore a welding cap is added to the housing; the upper part is then welded to the welding cap, and deformation of the inner cavity of the housing is avoided.
  • a further advantage of using metal injection moulding is that the housing can be made in steel. Using the conventional manufacturing methods it is hard and expensive to make a housing in steel, therefore brass is often used for a housing since it is easier to work in brass. However to manufacture the housing in steel is easy using metal injection moulding, it is efficient and cheap using a minimum of material.
  • Metal injection moulding can also be used for other metals like ceramics, magnetic materials, and combinations of different materials in same part.
  • the housing comprises an inner liner and the inner liner end and the welding cap end are separated by a groove.
  • the inner liner is defining the form of the inner cavity, the inner liner must be strait to keep the inner parts in place and avoid obstacles to the free movement of the inner parts.
  • the inner liner and the welding cap are placed side by side separated by a groove. The groove makes some distance between the welding cap and the inner liner so heat from the welding cannot deform the inner liner.
  • the end of the welding cap can be staggered compared to the end of the inner liner so the end of the inner liner is lower than the end of the welding cap avoiding the risk of the inner liner getting in contact with the upper part. Such a contact is unwanted since it might prevent a good contact between the welding cap and the upper part.
  • the upper part can comprise a guiding ring placed on the upper part so the guiding ring gets in contact with the inner edge of the welding cap.
  • the guiding ring helps placing and keeping the valve housing and the upper part in correct position for the welding.
  • the housing is manufactured so all parts of the housing have a uniform thickness. This is done to ensure that the debinding process and the sintering remove almost all the polymeric binder. In the preferred embodiment all parts of the housing is about 1 mm. Of course in areas where different part meets the thickness can be a little larger.
  • the dept of the welding seem should preferably be less than the thickness of the welding cap to avoid the risk of the inner liner is hit by molten material during welding risking deformation.
  • FIG. 1 shows a valve of the preferred embodiment of the valve.
  • FIG. 2 shows a 3-D drawing of the housing showing the welding cap and the inner liner of the invention.
  • FIG. 3 shows the housing seen from above.
  • FIG. 1 shows the preferred embodiment of the invention.
  • the valve 1 comprising a housing 2 , an inlet 3 , an outlet 4 , and an upper part 5 .
  • a guiding tube 6 around the guiding tube 6 the valve comprises a solenoid, but this is not shown on the drawing.
  • Inside the guiding tube 6 are an armature 7 and an armature top 8 .
  • a spring 9 keeps the valve closed when the armature 7 is not activated by the electromagnetic coil.
  • the housing 2 comprises an inner cavity 10 and a valve seat 11 and the nozzle 20 , in the inner cavity 10 is the inner parts comprising a servo piston 12 and a servo closure member 13 .
  • the housing further comprises a welding cap 14 , an inner liner 15 and a groove 16 , the groove 16 is placed between the welding cap 14 and the inner liner 15 .
  • the servo closure member 13 moves up and down in the inner cavity 10 .
  • the servo closure member 13 is following the inner liner 15 , therefore it is very important that the inner liner 15 is strait since bumps or other obstacles will hinder the free movement of the servo closure member 13 . This is the main reason the welding must not deform the inner liner 15 .
  • the upper part 5 can have a guiding ring (now shown), the guiding ring meets the inner edge of the welding cap 14 , so when the upper part 5 is placed on top of the housing 2 , the guiding ring ensure the upper part 5 is placed in the right place for welding.
  • FIG. 2 shows the housing 2 in a 3-d drawing.
  • the inner liner end 17 is staggered slightly lower than the welding cap end 18 so when the upper part 5 is placed on top of the housing 2 there is a small gab between the inner liner end 17 and the upper part 5 .
  • FIG. 3 shows the housing 2 seen from above with the welding cap 14 , the inner liner 15 , the groove 16 , the leaks 19 , the inner cavity 10 and the nozzle 20 .
  • the size of the nozzle 20 can be increased by cutting, so the nozzle 20 can be made in varying sizes to fit the wanted characteristics of the valve.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Valve Housings (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

A method to manufacture a valve using metal injection moulding is disclosed. The valve housing comprises a welding cap for welding the upper part of the valve to the valve housing. The welding cap is placed so the upper part can be welding to the housing without damaging the inner cavity of the housing. There is a gab between the welding cap and the inner liner so the heat from the welding to not damage the inner liner allowing the inner parts of the valve to move freely.

Description

    CROSS REFERENCE TO RELATED APPLICATIONS
  • This application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in International Patent Application No. PCT/DK2010/000107 filed on Jul. 14, 2010 and Danish Patent Application No. PA 2009 00925 filed Aug. 13, 2009.
    • FIELD OF THE INVENTION
  • The present invention relates to a method to manufacture a valve using metal injection moulding and welding the valve housing to the upper part of the valve without damaging the inner cavity of the valve housing.
    • BACKGROUND OF THE INVENTION
  • A valve housing is usually manufactured by forging or turning or a combination of those. In a traditional forging process it is difficult to manufacture details inside the valve and often further adaption of the housing is necessary after the forging giving extra work and also expensive material is wasted. When manufacturing a valve typically soldering or screw joints are used to assemble the housing to the other parts of the valve.
  • Metal injection moulding (MIM) is a manufacturing method that at relatively low costs allows manufacturing parts effectively and precise. In the MIM process metal powder is mixed with a polymeric binder. The MIM material is heated and then injected in a mould. The part obtained after the injection moulding is slightly larger in size than the final part. The part then goes through a debinding process where about 90% of the polymeric binder is removed. Then the part is sintered to remove the majority of the remaining polymeric binder and the sintering also makes the metal powder to fuse together creating a solid part. The sintering also makes the part shrink to its final size.
  • A problem by MIM is that the walls of the part have to be relatively thin to allow the debinding process and the sintering to remove almost all the polymeric binder. Therefore making parts to be welded by using the MIM process is difficult because thin walls easy deforms during welding.
    • SUMMERY OF THE INVENTION
  • It is the object of the invention to manufacture a valve as cheap as possible using a minimum of material by using the MIM process.
  • It is further the object of the invention to avoid damage to the inner cavity of the valve when the valve housing is welded to the upper part of the valve.
  • The problem of using the MIM process is that the relatively thin walls often will deform during welding.
  • The invention provides a method for manufacturing a valve, the valve comprising a housing and an upper part, the housing is manufactured by metal injection moulding, the housing comprises an welding cap, and the upper part is welded to the welding cap.
  • Using metal injection moulding makes it possible to manufacture the housing cheap using a minimum of material since the waste of material is very limited. However there is a problem using metal injection moulding because the thickness of the walls must be limited to allow for the debinding process and the sintering process to remove almost all of the polymeric binder. If the walls are too thick it is difficult to remove almost all of the polymeric binder. Therefore the walls must be relatively thin compared with a housing manufactured in a traditional way. Thin walls give a problem when the housing is welded to the upper part as the welding can deform the housing making it difficult for the inner parts to move freely. Therefore a welding cap is added to the housing; the upper part is then welded to the welding cap, and deformation of the inner cavity of the housing is avoided.
  • A further advantage of using metal injection moulding is that the housing can be made in steel. Using the conventional manufacturing methods it is hard and expensive to make a housing in steel, therefore brass is often used for a housing since it is easier to work in brass. However to manufacture the housing in steel is easy using metal injection moulding, it is efficient and cheap using a minimum of material.
  • Metal injection moulding can also be used for other metals like ceramics, magnetic materials, and combinations of different materials in same part.
  • The housing comprises an inner liner and the inner liner end and the welding cap end are separated by a groove. The inner liner is defining the form of the inner cavity, the inner liner must be strait to keep the inner parts in place and avoid obstacles to the free movement of the inner parts. The inner liner and the welding cap are placed side by side separated by a groove. The groove makes some distance between the welding cap and the inner liner so heat from the welding cannot deform the inner liner.
  • There is a passage between the groove and the inner cavity so no pressure can build up in the groove during welding or during operation of the valve.
  • The end of the welding cap can be staggered compared to the end of the inner liner so the end of the inner liner is lower than the end of the welding cap avoiding the risk of the inner liner getting in contact with the upper part. Such a contact is unwanted since it might prevent a good contact between the welding cap and the upper part.
  • Further the upper part can comprise a guiding ring placed on the upper part so the guiding ring gets in contact with the inner edge of the welding cap. The guiding ring helps placing and keeping the valve housing and the upper part in correct position for the welding.
  • Preferable the housing is manufactured so all parts of the housing have a uniform thickness. This is done to ensure that the debinding process and the sintering remove almost all the polymeric binder. In the preferred embodiment all parts of the housing is about 1 mm. Of course in areas where different part meets the thickness can be a little larger.
  • After welding the dept of the welding seem should preferably be less than the thickness of the welding cap to avoid the risk of the inner liner is hit by molten material during welding risking deformation.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 shows a valve of the preferred embodiment of the valve.
  • FIG. 2 shows a 3-D drawing of the housing showing the welding cap and the inner liner of the invention.
  • FIG. 3 shows the housing seen from above.
    •  DETAILED DESCRIPTION OF THE DRAWINGS
  • FIG. 1 shows the preferred embodiment of the invention. The valve 1 comprising a housing 2, an inlet 3, an outlet 4, and an upper part 5. To the upper part 5 is fixed a guiding tube 6, around the guiding tube 6 the valve comprises a solenoid, but this is not shown on the drawing. Inside the guiding tube 6 are an armature 7 and an armature top 8. A spring 9 keeps the valve closed when the armature 7 is not activated by the electromagnetic coil. The housing 2 comprises an inner cavity 10 and a valve seat 11 and the nozzle 20, in the inner cavity 10 is the inner parts comprising a servo piston 12 and a servo closure member 13. The housing further comprises a welding cap 14, an inner liner 15 and a groove 16, the groove 16 is placed between the welding cap 14 and the inner liner 15.
  • The servo closure member 13 moves up and down in the inner cavity 10. The servo closure member 13 is following the inner liner 15, therefore it is very important that the inner liner 15 is strait since bumps or other obstacles will hinder the free movement of the servo closure member 13. This is the main reason the welding must not deform the inner liner 15.
  • To make mounting easier the upper part 5 can have a guiding ring (now shown), the guiding ring meets the inner edge of the welding cap 14, so when the upper part 5 is placed on top of the housing 2, the guiding ring ensure the upper part 5 is placed in the right place for welding.
  • FIG. 2 shows the housing 2 in a 3-d drawing. There is the welding cap 14 and the inner liner 15 separated by the groove 16. The inner liner end 17 is staggered slightly lower than the welding cap end 18 so when the upper part 5 is placed on top of the housing 2 there is a small gab between the inner liner end 17 and the upper part 5. To be sure there is a free passage between the groove 16 and the inner cavity 10 there also can be made some leaks 19 in the inner liner 15.
  • FIG. 3 shows the housing 2 seen from above with the welding cap 14, the inner liner 15, the groove 16, the leaks 19, the inner cavity 10 and the nozzle 20. The size of the nozzle 20 can be increased by cutting, so the nozzle 20 can be made in varying sizes to fit the wanted characteristics of the valve.
  • Although the invention above has been described in connection with preferred embodiments of the invention, it will be evident for a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims.

Claims (7)

1. A method of manufacturing a valve, the valve comprising a housing and an upper part, wherein the housing is manufactured by metal injection moulding, the housing comprises a welding cap, and the upper part is welded to the welding cap.
2. The method of manufacturing a valve according to claim 1, wherein the housing comprises an inner liner, the inner liner and the welding cap are separated by a groove.
3. The method of manufacturing a valve according to claim 1, wherein there is a passage between the groove and a inner cavity.
4. The method of manufacturing a valve according to claim 1, wherein the welding cap end is staggered compared to the inner liner end.
5. The method of manufacturing a valve according to claim 1, wherein the upper part comprises a guiding ring meeting the inner edge of the welding cap.
6. The method of manufacturing a valve according to claim 1 wherein all parts of the housing have a uniform thickness.
7. The method of manufacturing a valve according to claim 1 wherein the dept of the welding seem are less that the thickness of the welding cap.
US13/389,543 2009-08-13 2010-07-14 Manufacturing method of a valve Abandoned US20120216404A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DKPA200900925 2009-08-13
DKPA200900925 2009-08-13
PCT/DK2010/000107 WO2011018087A1 (en) 2009-08-13 2010-07-14 Manufacturing method of a valve

Publications (1)

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US20120216404A1 true US20120216404A1 (en) 2012-08-30

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US13/389,543 Abandoned US20120216404A1 (en) 2009-08-13 2010-07-14 Manufacturing method of a valve

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US (1) US20120216404A1 (en)
EP (1) EP2464905B1 (en)
CN (1) CN102483175B (en)
MX (1) MX2012001807A (en)
RU (1) RU2499938C1 (en)
WO (1) WO2011018087A1 (en)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102840370B (en) * 2012-03-06 2013-11-06 浙江三花股份有限公司 Method for manufacturing electronic expansion valve
EP2963321B1 (en) 2013-02-27 2018-09-12 Zhejiang Sanhua Climate & Appliance Controls Group Co., Ltd. Electronic expansion valve and connection assembly therefor
WO2016034418A1 (en) 2014-09-01 2016-03-10 Danfoss A/S A valve with a welded valve housing

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4347209A (en) * 1979-07-19 1982-08-31 Yoshino Kogyosho Co., Ltd. Method for molding elongated parisons
US4988078A (en) * 1989-07-24 1991-01-29 Otteman John H High flow rate miniature valve

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1066394B (en) * 1959-10-01
US2292780A (en) * 1940-02-14 1942-08-11 American Chain & Cable Co Valve
IT1054567B (en) * 1975-02-10 1981-11-30 Acf Ind Inc MEANS AND METHOD FOR THE REPAIR OF VALVES
IT1096961B (en) * 1978-07-05 1985-08-26 Nuovo Pignone Spa BALL-TYPE PERFECTED INTERCEPTION VALVE AND WELDED EXTERNAL BODY
DK715553T1 (en) * 1993-08-23 1997-08-25 Danfoss As Valve, especially expansion valve for refrigeration plant, and method of manufacture thereof
AU6459198A (en) * 1997-03-11 1998-09-29 Kelsey-Hayes Company Sleeve and armature subassembly for control valves of vehicular braking systems and method of forming
DE10010499A1 (en) * 2000-03-07 2001-09-27 Josch Strahlschweistechnik Gmb VaIve housing center section has pipe connectors welded in pipe with weld depths which vary circumferentially depending upon outer diameter and wall thickness of pipe and angle and inclination of pipe connectors to pipe axis
CN1190610C (en) * 2002-05-29 2005-02-23 刘时通 Method for manufacturing valve body
DE102006047917A1 (en) * 2006-10-10 2008-04-17 Robert Bosch Gmbh Valve body and associated solenoid valve

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4347209A (en) * 1979-07-19 1982-08-31 Yoshino Kogyosho Co., Ltd. Method for molding elongated parisons
US4988078A (en) * 1989-07-24 1991-01-29 Otteman John H High flow rate miniature valve

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Publication number Publication date
RU2012108677A (en) 2013-09-20
EP2464905A1 (en) 2012-06-20
CN102483175B (en) 2014-08-27
RU2499938C1 (en) 2013-11-27
CN102483175A (en) 2012-05-30
EP2464905B1 (en) 2013-08-21
WO2011018087A1 (en) 2011-02-17
MX2012001807A (en) 2012-03-16

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Owner name: DANFOSS A/S, DENMARK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HOEJLAND HOEYER, JESPER;PETERSEN, HANS KURT;BONDE, ERIK THOMAS;AND OTHERS;SIGNING DATES FROM 20120413 TO 20120416;REEL/FRAME:028219/0821

STCB Information on status: application discontinuation

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