Adjustable Thermostatic Valve Control Gap
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Solution Overview
Problem
Existing thermostatic mixing valves face challenges in maintaining consistent temperature control due to manufacturing tolerances, requiring complex manufacturing and assembly processes, and necessitating re-adjustment of the control gap during valve replacement.
Innovation Solution
A thermostatic valve design featuring a double valve seat slide with a housing split into two parts, allowing for precise adjustment of the control gap through a threaded connection, which can be secured with adhesive or ultrasonic welding to maintain set quality and allow for re-adjustment as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the control gap is precisely manufactured to achieve defined control behavior, then temperature control quality is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The housing is divided into two separate parts (first housing part and second housing part) that can be adjusted relative to each other. This segmentation allows the control gap to be precisely set by positioning the valve body between the two housing parts, rather than requiring precise manufacturing of the entire housing as a single piece.
Solution Approach 2:
The control gap is pre-adjusted during assembly by positioning the valve body between the two housing parts and securing them together. This preliminary adjustment ensures the defined control behavior is achieved before the valve is installed and used, avoiding the need for complex precision manufacturing while maintaining temperature control quality.
2Manufacturing precision
If the control gap is adjusted during installation, then temperature control quality is improved, but assembly time and complexity increase
Solution Approach 1:
The control gap adjustment is performed as part of the initial assembly process when the two housing parts are joined together. The valve body is positioned between the housing parts and the control gap is set during this single assembly operation, rather than requiring separate adjustment steps after installation.
Solution Approach 2:
The separable housing design allows the control gap to be adjusted by simply positioning the valve body between the two housing parts during assembly. The housing parts are then secured together to fix the adjustment, making the process efficient and integrated into the assembly workflow.
3Ease of manufacture
If the housing is made as a single piece, then manufacturing simplicity is maintained, but control gap adjustment capability is lost
Solution Approach 1:
The housing is divided into two parts that can be adjusted relative to each other to change the control gap, while still being simple enough to manufacture. Each housing part can be produced separately with standard tolerances, and the adjustability is achieved through their relative positioning rather than complex features on a single piece.
Solution Approach 2:
The housing design transitions from a static single-piece structure to a dynamic adjustable structure where the two housing parts can be positioned at different distances from each other. This allows the control gap to be adapted to different requirements while maintaining manufacturing simplicity through the use of standard fastening and positioning features.
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 design enables a thermostatic valve with defined control behavior and reduced manufacturing and assembly costs, ensuring consistent temperature control without the need for complex manufacturing processes and allowing for easy re-adjustment of the control gap.
Implementation Method 1
a control element comprising a thermostatic temperature sensor and a valve body
Implementation Method 2
The control element has a tappet which can be deflectable in the axial direction and which acts on an expansion element arranged in a thermostat housing
Data Source
Figure 1
AI summary
The valve has a valve insert (100) with inlets (3a, 3b) for liquid e.g. cold and hot water, and an outlet (16). A regulating element (6) has a valve body (7) that is axially movable in the insert to adjust the inlets and works against force of a return spring (13). The body is arranged between valve seats (8, 9) provided at the insert. The insert is formed of a head piece (1) and a base part (2) such that the seats are respectively formed at the piece and the base part that are linearly movably arranged together such that a distance between the piece and the base part is freely adjustable.