Multi-Channel Disc Valve Assembly With Single-Actuator Flow Mixing
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Solution Overview
Problem
Current multi-way valves, particularly in automotive cooling systems, are bulky, expensive, and require multiple actuators due to the need for precision in creating fluid-tight seals, limiting their utility and increasing complexity, especially in hybrid vehicle applications where more complex cooling arrangements are needed.
Innovation Solution
A multi-channel disc valve assembly with a modified central mixing chamber structure and movable discs, utilizing sealing elements and a single actuator to control fluid flow through multiple pathways, allowing for scalable and cost-effective fluid control with reduced complexity and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-way ball valves are used to control fluid flow, then fluid flow control is achieved, but the device becomes bulky and expensive to manufacture
Solution Approach 1:
The valve body is divided into multiple separate channels that can be manufactured independently and then assembled together. This segmentation allows each channel to be produced using standard, cost-effective manufacturing processes rather than requiring complex precision machining of a single integrated valve body, thereby reducing manufacturing costs while maintaining multi-way flow control capability
Solution Approach 2:
The valve design uses a universal disc component that can be configured to control flow in multiple directions and pathways. This single disc mechanism serves multiple functions by selectively blocking or allowing flow through different channels, replacing the need for multiple specialized ball valves and reducing overall system complexity and manufacturing cost
2Reliability
If precision sealing is implemented in multi-way valves, then fluid-tightness is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs simple, replaceable sealing elements that can be manufactured as inexpensive components. These sealing elements are designed to be easily replaced if worn or damaged, rather than requiring precision-machined permanent seals. This approach maintains fluid-tightness while significantly reducing manufacturing complexity and cost
Solution Approach 2:
The valve utilizes flexible sealing elements or thin film seals that conform to the channel surfaces to create fluid-tight barriers. These flexible seals are simpler to manufacture than rigid precision seals and can accommodate minor manufacturing tolerances, thereby maintaining reliability without increasing device complexity
3Ease of operation
If multiple actuators are used to control each ball individually, then precise flow control is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple flow control functions into a single disc mechanism that can be actuated by one actuator. The disc is positioned and oriented to simultaneously control flow in multiple channels through its rotation, merging what would traditionally require multiple separate actuators into a single control system, thereby reducing device complexity while maintaining precise flow control
Solution Approach 2:
A single actuator is designed to control the disc valve's position, enabling one actuator to perform multiple control functions across different flow pathways. This universal actuator replaces multiple specialized actuators, simplifying the control system while maintaining the ability to precisely regulate flow in each channel through the disc's angular position
4Reliability
If single-unit valve production is used to ensure fluid-tightness, then sealing is improved, but adaptability to different applications is limited
Solution Approach 1:
The valve system is segmented into modular components including interchangeable channel assemblies and configurable disc elements. This segmentation allows different channel configurations to be assembled to match specific application requirements while maintaining fluid-tight seals through standardized sealing interfaces, thereby providing adaptability without compromising reliability
Data Source
AI summary
A multi-channel disc valve assembly including: a first inlet chamber having a first inlet port; a second inlet chamber having a second inlet port; a multi-channel mixing chamber body having at least one first chamber opening fluidly communicable with the first inlet chamber and at least one second chamber opening fluidly communicable with the second inlet chamber; a first disc valve sub-assembly positioned between the first inlet chamber and the multi-channel mixing chamber body, the first disc valve sub-assembly including a first movable disc; and a second disc valve sub-assembly positioned between the second inlet chamber and the multi-channel mixing chamber body, the second disc valve sub-assembly including a second movable disc; the first and second movable discs being rotatable to respectively alter fluid flow pathways from the first inlet chamber to the multi-channel mixing chamber body and from the second inlet chamber to the multi-channel mixing chamber body.