Compressor System Pressure Control Without Relief Valve
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing compressor systems for puncture repair kits require relief valves and one-way valves, which increase production costs and complexity, and can cause reverse flow of puncture sealant due to excessive pressure release, leading to inefficiencies and increased costs.
Innovation Solution
A compressor system that controls air pressure without a relief valve by using a motor-driven piston with a specific compression volume and air intake valve design, ensuring the pressure remains at or below a specified level, and eliminating the need for a one-way valve in the flow passage to prevent reverse sealant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a relief valve is used to control compressed air pressure, then the pressure can be controlled at a specified level or lower, but the device complexity and production cost increase due to multiple components and adjusting operations
Solution Approach 1:
The patent removes the relief valve component from the compressor system by extracting its pressure control function and integrating it into the air intake valve mechanism. The air intake valve is designed with a specific opening pressure characteristic that automatically limits the maximum pressure in the surge chamber, eliminating the need for a separate relief valve and reducing device complexity.
Solution Approach 2:
The air intake valve is designed to serve multiple functions: it controls air intake during the compression stroke and simultaneously acts as a pressure-limiting mechanism through its specific opening pressure characteristic. This multi-functionality replaces the need for separate relief valve components, reducing overall system complexity while maintaining pressure control.
2Reliability
If a relief valve is used to release excessive pressure, then overpressure protection is achieved, but production time and labor increase due to required adjusting operations for each valve
Solution Approach 1:
The patent eliminates the relief valve component and its associated adjusting operations by extracting the pressure control function and integrating it into the air intake valve mechanism. The air intake valve is designed with a specific opening pressure characteristic that automatically limits the maximum pressure in the surge chamber, eliminating the need for a separate relief valve and reducing device complexity.
Solution Approach 2:
The air intake valve automatically performs pressure control without requiring external adjusting operations. The valve's specific opening pressure characteristic ensures that it closes automatically when the surge chamber pressure reaches the specified level, providing self-regulating pressure control that eliminates the need for manual adjustment during assembly.
3Stress or pressure
If a relief valve opens to release excessive pressure, then pressure control is achieved, but reverse flow of puncture sealant occurs toward the surge chamber
Solution Approach 1:
The patent removes the relief valve component that causes reverse flow by extracting its pressure control function and integrating it into the air intake valve mechanism. The air intake valve is designed with a specific opening pressure characteristic that automatically limits the maximum pressure in the surge chamber, eliminating the need for a separate relief valve and reducing device complexity.
Solution Approach 2:
Instead of using a relief valve that opens to release pressure (which causes reverse flow), the patent inverts the approach by using an air intake valve that closes to limit pressure. The valve closes automatically when the surge chamber pressure reaches the specified level, preventing overpressure without creating the pressure differential that causes reverse sealant flow.
4Object-generated harmful factors
If a one-way valve is added to prevent reverse sealant flow, then sealant flow control is improved, but device complexity and production cost increase
Solution Approach 1:
The patent eliminates the need for a one-way valve by extracting the pressure control function from a separate relief valve and integrating it into the air intake valve mechanism. The air intake valve's specific opening pressure characteristic automatically limits pressure and prevents reverse flow, making the additional one-way valve unnecessary and reducing device complexity.
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 solution allows for efficient pressure control within the specified limits, reducing production costs and preventing reverse flow of sealant, thereby enhancing productivity and safety without the need for additional valve components.
Implementation Method 1
a piston (5) reciprocably disposed in the cylinder (7), and a pump chamber (6A) for compressing air between the piston (5) and itself
Implementation Method 2
an air release valve (13) allowing the compressed air to move to a surge chamber (6B)
Implementation Method 3
a air intake valve (12) having an air intake hole (12A) penetrating through the piston (5) to take outside air into the pump chamber (6A), and a valving element (12B) formed from a leaf spring closing a pump chamber side of the air intake hole (12A) with its elasticity
Data Source
AI summary
The pressure of compressed air supplied to an object to be filled with air is controlled at a specified pressure or less without using a relief valve. Given that a cylinder volume (stroke volume) during a piston moves from the lower dead point to the top dead point is V1, a cylinder volume (compression volume) when the piston reaches the top dead point is V2, the atmospheric pressure is P0, and the specified pressure is PP, the compression volume V2 in the compressor system satisfies the following expression (1). The diameter D of the air intake hole of an air intake valve provided on the piston is 3 to 15 mm.0.8×{V1×P0/(PP−P0)}=<V2<1.0×{V1×P0/(PP−P0)} (1)