Dual-Path Flow Regulator With Anti-Jamming Piston Bore
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flow rate regulators for heating and cooling systems are prone to jamming due to dirt or limescale deposits, require complex and costly designs, and have alignment issues during installation, leading to increased production difficulties and part counts.
Innovation Solution
A flow rate regulator design featuring a bore through the first and diaphragm piston, eliminating the need for inclined housing bores and additional sleeves, using a perforated membrane with beads for sealing, and a conically tapered piston to prevent sticking, with PTFE materials to reduce limescale adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a precisely fitting piston guidance with small gaps is used, then the piston can be accurately positioned, but the small gaps tend to jam with dirt or limescale deposits
Solution Approach 1:
The patent changes the geometric parameters of the piston guidance from tight-fitting small gaps to larger clearance gaps. This parameter change allows the piston to move reliably without jamming while still achieving sufficient positioning accuracy for flow regulation, thus resolving the contradiction between precision and reliability.
2Reliability
If an inclined bore is formed in the housing to transmit differential pressure, then the pressure transmission is achieved, but the machining direction no longer corresponds to the normal clamping, increasing production costs
Solution Approach 1:
Instead of forming an inclined bore in the housing at an awkward angle, the patent inverts the approach by forming axial bores in the pistons themselves that are perpendicular to the housing clamping direction. This allows standard machining operations to be used, reducing production costs while achieving the same pressure transmission function.
Solution Approach 2:
The patent introduces the piston as an intermediary element that contains the pressure transmission bores. Rather than directly forming complex inclined bores in the housing, the piston mediates the pressure transmission from the valve seat to the membrane, simplifying the housing structure and machining requirements.
3Reliability
If additional sleeves and O-ring seals are used to seal the membrane cap, then reliable sealing is achieved, but the number of parts and production complexity increase
Solution Approach 1:
The patent merges the sealing function into the membrane assembly itself by using the membrane's inherent flexibility and the clamping arrangement to create a seal between the membrane cap and housing. This eliminates the need for separate O-ring seals and reduces the number of parts, while maintaining reliable sealing through the integrated design.
Solution Approach 2:
The patent extracts the sealing function from separate components (O-rings, sleeves) and integrates it into the membrane and cap assembly. By taking out the dedicated sealing elements and incorporating sealing capability into existing structural components, the design reduces part count while maintaining sealing reliability.
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 design minimizes production costs, reduces part count, prevents jamming, and ensures reliable sealing and alignment, while maintaining effective flow regulation and longevity.
Implementation Method 1
The differential pressure produced by the flow rate in the first flow path across the piston valve seat between the inlet side and the outlet side is transmitted via a channel to the side of the diaphragm piston that is sealed off from the flow path
Implementation Method 2
the first piston having a membrane with a membrane piston is held in a sealed, movable manner in a housing cap
Data Source
Figure 1
Figure 2
Figure 3
AI summary
To create a flow rate controller (1) for heating and/or cooling systems, which has two separate flow paths (2; 3), wherein a differential pressure-controlled actuator (4) with a first piston (5) and a piston valve seat (7) interacting with it is arranged in the first flow path (2), wherein the stroke movement of the first piston (5) is transmitted to a second piston (6) located in the second flow path (3), so that the flow rate in the second flow path (3) is controllable, wherein the first piston (5) is movably held in a housing cap (9) sealed by a diaphragm (8) with a diaphragm piston (15), and the differential pressure arising from the flow rate in the first flow path (2) across the piston valve seat (7) between the inlet side (11) and outlet side (12) is transmitted via a channel to the side of the diaphragm piston (15) sealed against the flow path (2),which is particularly cost-effective to manufacture and in which the number of parts required is minimized, it is proposed that the channel be formed by a bore (13) passing through the first piston (5) and the diaphragm piston (15), which opens into the outlet side (12) via a transverse bore (14).