Axial Valve Insert Modular Assembly for Variant Reduction
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Solution Overview
Problem
Conventional filter devices require separate assembly and storage of non-return and thermostatic valves, leading to increased costs and logistical challenges due to the need for multiple variants for different vehicle applications.
Innovation Solution
A modular system allowing for flexible assembly of axial flow valve inserts with a non-return valve and a coaxially attachable cover or bypass valve, including a blind plug for closing bypass channels, using a clip connection for easy installation, enabling various variants to be produced without extensive storage or logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-return valves and thermostatic valves are installed in separate locations, then the valve functions are independent and reliable, but the installation effort and device complexity increase considerably
Solution Approach 1:
The patent combines the non-return valve and thermostatic valve into a single integrated valve insert that is axially flowable. The non-return valve is positioned downstream of the thermostatic valve within the same housing, allowing both functions to coexist in one component. This merging reduces installation complexity while maintaining functional independence through spatial separation and directional flow control.
Solution Approach 2:
The integrated valve insert is segmented into distinct functional zones: the thermostatic valve section with its bypass channel and the non-return valve section with its check valve mechanism. This segmentation allows each valve type to operate independently with its own control logic while being housed in a single axially flowable unit, resolving the contradiction between integration and functional independence.
2Adaptability or versatility
If different versions of non-return valves are kept for different vehicle variants, then each vehicle variant gets the correct valve version, but storage and logistics costs increase
Solution Approach 1:
The valve insert is designed as a universal component that can serve multiple vehicle variants through optional configurations. The housing includes standardized connection elements that allow different end pieces (with or without integrated non-return valves, with different thread types) to be attached to the same base unit. This universality enables a single core design to adapt to various application requirements without maintaining separate inventory for each variant.
Solution Approach 2:
The system allows dynamic configuration of the valve insert based on vehicle variant requirements. The non-return valve functionality can be activated or deactivated by selecting different end piece configurations, and the bypass channel can be opened or closed depending on the installed components. This dynamic adaptability reduces the need for multiple static versions in inventory.
3Ease of operation
If pre-assembled non-return valve units are installed, then installation is simplified, but storage and logistics costs increase due to multiple variants
Solution Approach 1:
The valve insert is segmented into a standardized base housing and interchangeable end pieces. The base housing contains the thermostatic valve and bypass channel, while separate end pieces provide different configurations (including or excluding non-return valves, different connection types). This segmentation allows customers to order a single base unit with different end pieces as needed, simplifying installation while reducing variant inventory.
4Adaptability or versatility
If a modular system with multiple attachable components is used, then flexibility and adaptability increase, but device complexity increases
Solution Approach 1:
The modular system is segmented into clearly defined components with standardized interfaces: a base housing with integrated thermostatic valve, various end pieces with different functionalities, and connection elements. Each component has a specific function and standardized mounting interfaces, which reduces assembly complexity despite the variety of configurations available. The segmentation allows for systematic assembly rather than complex integration.
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
Enables efficient, flexible, and cost-effective production of valve inserts that can be assembled directly at the installation site, reducing storage needs and improving flow resistance, thus lowering energy consumption and logistical complexities.
Implementation Method 1
Conventional filter systems, such as oil filters or oil modules, employ thermostatic valves that divert the oil past the oil cooler during the cold start phase
Implementation Method 2
such an oil circuit incorporates a non-return valve that prevents the filter system from draining when the engine is switched off, ensuring that the required oil pressure is restored relatively quickly upon restarting
Implementation Method 3
the non-return valve can be connected to the cover, the bypass valve, or the blanking plug via a clip connection
Data Source
Figure 1~2
Figure 3~6
AI summary
The invention relates to a modular system (8) for an axially flowable valve insert (1) with a non-return valve (2) and a coaxially attachable cover (9) and/or a bypass valve (3). This allows for significantly greater flexibility with regard to variants.