Additively Manufactured Valve Assembly With Integral Preload
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Solution Overview
Problem
Conventional valve manufacturing methods require multiple parts, leading to complex assembly processes and increased part counts, which can be time-consuming and costly, and often necessitate custom tooling and labor-intensive processes to achieve the required pre-loading mechanisms.
Innovation Solution
The use of additive manufacturing, specifically Laser Powder Bed Fusion, allows for the creation of integrally formed valve assemblies with reduced part counts by incorporating helical grooves and biasing convolutions directly into the poppet-carrying portion, eliminating the need for separate springs and custom tooling, and enabling a unitary configuration that provides pre-loading without extensive labor or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional valve manufacturing methods are used with multiple parts, then the valve assembly can be manufactured with standard components, but the assembly process becomes complex and time-consuming with increased part counts
Solution Approach 1:
The patent combines multiple separate valve components (body, spring, poppet, keeper) into a single integrally formed valve assembly manufactured by additive manufacturing. The poppet-carrying portion is formed as one piece with the spring and poppet integrated, eliminating the need for separate components and complex assembly procedures while maintaining all necessary valve functions.
Solution Approach 2:
The single integrally formed valve assembly performs multiple functions that traditionally required separate components: the poppet-carrying portion provides both the poppet seating surface and the spring mounting structure, while the spring itself is formed as part of the same component. This multi-functional design reduces part count and simplifies manufacturing.
2Productivity
If conventional valve manufacturing methods are used with multiple parts, then standard components can be used, but production time and cost increase due to labor-intensive assembly processes
Solution Approach 1:
By merging multiple components into a single additively manufactured part, the patent eliminates time-consuming assembly operations. The integrally formed valve assembly requires minimal assembly steps compared to traditional multi-component valves, directly improving production efficiency and reducing assembly time.
Solution Approach 2:
The additive manufacturing process creates the pre-loaded spring mechanism and complex geometries directly during manufacturing, without requiring separate assembly operations or custom tooling. The valve assembly essentially manufactures itself in a single process, eliminating labor-intensive post-manufacturing assembly steps.
3Ease of manufacture
If conventional valve manufacturing methods are used, then traditional manufacturing processes can be employed, but custom tooling and labor-intensive processes are required to achieve pre-loading mechanisms
Solution Approach 1:
The spring and poppet-carrying portion are merged into a single integrally formed component through additive manufacturing. The spring is formed as an integral part of the poppet-carrying portion, eliminating the need for separate spring installation and pre-loading mechanisms that would require custom tooling in traditional manufacturing.
Solution Approach 2:
The patent changes the manufacturing parameter from conventional subtractive or formative methods to additive manufacturing, which enables the creation of complex pre-loaded spring mechanisms and integral structures that are impossible to achieve with traditional methods. This parameter change eliminates the need for custom tooling and complex pre-loading procedures.
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 approach results in a more efficient and cost-effective production of valve assemblies with reduced part counts, maintaining or improving performance compared to traditional valves, while simplifying the manufacturing process and eliminating the need for custom pre-loading mechanisms.
Implementation Method 1
the at least one convolution may be configured to compress and provide compliance such that the poppet head is movable relative to the closure
Data Source
AI summary
A valve assembly has a housing and a poppet-carrying portion. The housing includes an inlet port, an outlet port, an opening, and a assembly portion including helical grooves. The poppet-carrying portion is configured to be inserted through the opening and engage with the assembly portion. The poppet-carrying portion comprises a poppet head, a closure including protruding arms, convolutions, and a stopping portion. The convolutions extend between the poppet head and the closure and provide compliance such that the poppet head is movable relative to the closure. The stopping portion extends from the closure toward the poppet head and is spaced apart from the poppet head by a maximum compression distance. At a first fluid pressure, the protruding arms engage with the helical grooves, and the poppet head is positioned in a pre-load position that prevents the fluid from discharging through the outlet port.