Power element for refrigerant modulating valve
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Solution Overview
Problem
Conventional refrigerant expansion valves are costly to convert from thermostatic expansion valves (TEVs) to electronic expansion valves (EEVs), requiring numerous additional components and increased labor, necessitating a simpler and more cost-effective replacement solution.
Innovation Solution
An electronic modulating valve with an electrically actuated valve member, an electric power element, and an electronic controller that includes a probe for sensing mechanical vibrations and a refrigerant leak sensor, utilizing closed-loop control logic to manage valve operation, thereby reducing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermostatic expansion valves (TEVs) are replaced with electronic expansion valves (EEVs), then valve control precision and system efficiency are improved, but device complexity and conversion cost increase significantly
Solution Approach 1:
The patent combines the controller, power element, and valve body into an integrated assembly where the controller is mounted directly on the valve body and the power element is positioned within the valve assembly. This merging eliminates the need for separate mounting brackets, external wiring harnesses, and additional fastening hardware, thereby reducing device complexity while maintaining electronic control precision.
Solution Approach 2:
The valve body serves multiple functions: it houses the internal valve mechanism, provides mounting surfaces for the controller, acts as a structural support for the power element, and includes integrated fluid passages. This multi-functionality reduces the number of separate components needed, simplifying the overall device structure while preserving precise electronic control capabilities.
2Adaptability or versatility
If numerous additional components are added for TEV to EEV conversion, then valve functionality and control capability are enhanced, but installation labor and conversion cost increase
Solution Approach 1:
The controller, power element, and associated wiring are pre-assembled and pre-positioned on the valve body during manufacturing. This preliminary action ensures that all components are correctly aligned and secured before field installation, eliminating the need for technicians to perform complex assembly procedures and reducing installation time significantly.
Solution Approach 2:
The power element is positioned within the valve assembly structure, with the controller mounted on the valve body surface. This nested arrangement allows multiple components to occupy overlapping spatial volumes, reducing the overall footprint and minimizing the number of separate mounting locations required, thereby simplifying installation.
3Reliability
If traditional EEV components are used, then reliable refrigerant flow control is achieved, but system cost and component count increase
Solution Approach 1:
By integrating the controller, power element, and valve body into a single assembly, the patent reduces the total component count while maintaining reliable electronic control of refrigerant flow. The integrated design ensures proper alignment and connection between components, preserving control reliability without requiring additional separate parts.
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 electronic modulating valve provides a simpler and more cost-effective solution for refrigerant flow control, enhancing valve reliability, reducing warranty costs, and improving system efficiency by using mechanical vibration sensing and closed-loop control, while minimizing the need for additional sensors and wiring.
Implementation Method 1
a probe configured to sense a mechanical vibration in the refrigerant system
Implementation Method 2
an electrically actuated valve member mounted in the valve body, the valve member being movable within the valve body to modulate flow of fluid
Data Source
AI summary
An electronic modulating valve for a refrigerant system including a valve body; an electrically actuated valve member mounted in the valve body for modulating flow of fluid through the valve body; an electric power element having at least a portion of an electric actuator; and an electronic controller operably connected to the actuator, in which the actuator is operably connected to the valve member to control movement of the valve member in response to commands from the controller. The valve may include a probe configured to sense a mechanical vibration in the system and/or a refrigerant leak sensor. The controller receives information from the probe and/or leak sensor and controls movement of the valve member via the actuator in response to the information. The controller may be configured with a closed-loop logic architecture to control movement of the valve member via the electric actuator.