Composite Valve Assembly for Lightweight Solenoid Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional valve assemblies in automatic transmissions for vehicles require complex and costly metal structures for support and electrical power distribution, leading to increased design and manufacturing costs, weight, and potential mechanical issues with solenoid movement.
Innovation Solution
A valve assembly with a polymeric valve support and tray design that integrates solenoids and an electrical power distribution device, using a wire harness and polymeric materials with glass fiber reinforcement for reduced weight and cost, and improved mechanical stability, allowing direct connection of electrical wires to solenoids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal structures are used for valve support and electrical power distribution, then structural strength and stability are improved, but design and manufacturing costs increase, weight increases, and mechanical issues with solenoid movement may occur
Solution Approach 1:
The patent employs a composite material system consisting of a polymeric valve support body with embedded metal reinforcement ribs and metal connector portions. This composite approach allows the polymeric material to provide cost-effective, lightweight, and corrosion-resistant properties while the metal ribs and connectors supply the necessary structural strength and stability for solenoid mounting and electrical power distribution. The combination resolves the contradiction by achieving both low cost and high strength through material hybridization.
Solution Approach 2:
The valve support structure is segmented into distinct functional zones: polymeric body portions for cost-effective support, metal reinforcement ribs for structural strength, and metal connector portions for electrical connections. This segmentation allows each material to be used where it provides the most benefit, optimizing both cost and performance simultaneously.
2Stability of the object's composition
If metal structures are used for valve support and electrical power distribution, then structural stability is improved, but weight increases
Solution Approach 1:
The composite construction using polymeric material with metal reinforcement ribs creates a structure that is both lightweight and stable. The polymeric base material provides low weight and corrosion resistance, while the strategically placed metal ribs provide structural stability for solenoid mounting without requiring full metal construction, thus reducing overall weight while maintaining necessary stability.
Solution Approach 2:
Metal reinforcement ribs are placed locally only where structural stability is critically needed for solenoid mounting and electrical connector attachment, rather than using metal throughout the entire valve support structure. This localized reinforcement minimizes weight while providing stability precisely where required.
3Reliability
If complex metal structures are used for electrical power distribution, then reliability is improved, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The electrical power distribution function is merged with the valve support structure itself through metal connector portions that are integrally formed with or attached to the polymeric body. This eliminates the need for separate complex metal electrical distribution structures, reducing manufacturing costs and assembly steps while maintaining reliable electrical connections to solenoids through the integrated connector design.
Solution Approach 2:
The integration of metal connector portions within the polymeric valve support structure creates a composite assembly that provides both structural and electrical functions in a single manufactured component, simplifying production and reducing costs compared to assembling separate metal electrical distribution components.
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
The solution reduces design and manufacturing costs, decreases weight, enhances mechanical stability, and simplifies assembly by using polymeric materials and a wire harness, improving fuel economy and reliability in vehicle transmissions.
Implementation Method 1
The plurality of solenoids are directly mounted to the valve support for controlling a flow of fluid
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A valve assembly for use in an actuation assembly, with the actuation assembly including an actuation housing, includes a valve support adapted to be coupled to the actuation housing. The valve support has a body portion defining a plurality of solenoid bores. The valve assembly also includes a plurality of solenoids with each one of the plurality of solenoids disposed within a corresponding one of the plurality of solenoid bores and directly mounted to the valve support for controlling a flow of fluid. The valve assembly further includes an electrical power distribution device at least partially coupled to the valve support and connected to each of the plurality of solenoids. The valve assembly also includes a tray coupled to the body portion of the valve support to support a portion of the electrical power distribution device.