Electric Valve Inner Part Assembly for Low-Cost Fluid Communication
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Solution Overview
Problem
Conventional electric valves face high production costs due to complex mold requirements and potential defects from insertion molding, particularly when forming communication holes for pressure stabilization between compartments.
Innovation Solution
The electric valve design incorporates a resin inner part with uneven portions on its outer surface, press-fitted into a metal body, forming gaps for compartment communication without requiring a complex mold, allowing for stable fluid flow and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If insertion molding is used to integrate resin inner part with metal body, then productivity is improved, but manufacturing precision deteriorates due to potential defects and complex mold requirements
Solution Approach 1:
The invention divides the inner part into multiple sections (first inner part and second inner part) that can be formed separately and then assembled. This segmentation allows each part to be molded independently with simpler molds, avoiding the complexity of forming integrated communication holes through a single complex mold, thereby improving both productivity and manufacturing precision.
Solution Approach 2:
The invention employs nested assembly where the first inner part is inserted into the metal body, and the second inner part is inserted into the first inner part. This nested structure enables modular assembly with simpler individual components, eliminating the need for complex integrated molding while maintaining productivity through streamlined manufacturing processes.
2Adaptability or versatility
If communication holes are formed in the inner part, then fluid communication between compartments is improved, but device complexity increases due to mold requirements
Solution Approach 1:
The communication function is segmented across multiple parts. The first inner part has a first communication hole, and the second inner part has a second communication hole. This segmentation allows each part to have simpler, easier-to-manufacture communication features without requiring complex integrated molding, thus improving adaptability while reducing device complexity.
Solution Approach 2:
The invention creates fluid communication pathways through axial insertion of nested parts rather than through complex lateral communication holes in a single part. This dimensional approach (using the axial dimension for communication) simplifies the mold requirements while maintaining effective fluid communication between compartments.
3Device complexity
If integrated molding is used, then device complexity is reduced, but productivity deteriorates due to defect risks and rework requirements
Solution Approach 1:
By segmenting the inner part into multiple simpler components that can be manufactured independently with lower defect rates, the overall productivity improves despite the assembly step. The simpler molds required for each segment reduce rework and scrap, compensating for the additional assembly operation.
Solution Approach 2:
The inner parts are pre-formed as separate components with their communication holes already integrated into each segment. This preliminary formation of functional features in simpler molds eliminates the need for complex post-molding operations, improving productivity while maintaining structural efficiency.
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 configuration stabilizes fluid communication between compartments, reduces production costs, and prevents thermal deformation of the inner part, while enabling a wider selection of resin materials and improved productivity.
Implementation Method 1
a resin inner part with uneven portions on an outer surface, press-fitted into the metal body
Implementation Method 2
press-fitted into the metal body, forming gaps for compartment communication
Data Source
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AI summary
An object is to provide an electric valve that allows production cost to be kept down compared to conventional counterparts. The electric valve 10 includes a metal body 12 having a rotor compartment 13 accommodating a rotor 30 of a motor and a valve element compartment 14 accommodating a valve element 72 and communicating with a valve port, and a resin inner part 60 inside the body separating the rotor compartment 13 from the valve element compartment 14. A shaft 70 that rotates with the rotor 30 passes through a through hole 60H extending through the inner part 60, and has the valve element 72 disposed in a tip of the shaft. Rotation of the rotor 30 is converted to linear motion of the valve element 72 by engagement between respective threads formed in the through hole 60H and the shaft 70. The inner part 60 is press-fitted and fixed in a press-fit reception portion 41 between the rotor compartment 13 and the valve element compartment 14 inside the body 12. The inner part 60 is formed with an uneven portion 60A on an outer surface of the inner part, which forms a gap between the inner part and an inner surface of the body 12 so that the rotor compartment 13 and the valve element compartment 14 communicate with each other.