Engine Flap Valve Seat Design for Tight Sealing and Low Flow Resistance
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Solution Overview
Problem
Existing flap devices for internal combustion engines as 3/2-way valves fail to ensure a tight seal in both end positions, and their installation is often dependent on a large and difficult-to-access connection housing.
Innovation Solution
A flap device with dimensionally stable flap plates and a flexible sealing element that rests perpendicularly on valve seat surfaces in both end positions, forming a cylindrical plug-in valve design with increased contact surface area for enhanced tightness, allowing for independent installation and tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve seat surfaces are formed on the connection housing, then the tightness is improved, but the manufacturing complexity and accessibility are worsened due to the large and difficult-to-access housing
Solution Approach 1:
The valve device is segmented into a modular design where the valve body with integrated valve seat surfaces can be manufactured separately and then installed into the connection housing. This segmentation allows the valve seat surfaces to be formed on the valve body in a controlled manufacturing environment rather than on the large connection housing, improving both tightness and manufacturing accessibility.
2Device complexity
If the flap body rests against the channel walls for sealing, then the structure is simple, but the tightness is insufficient for all applications
Solution Approach 1:
A sealing element is introduced as an intermediary component between the flap body and the valve seat surfaces. This sealing element enhances the tightness by providing a dedicated sealing interface, while the overall structure remains relatively simple. The sealing element acts as a mediator that ensures reliable sealing without requiring complex structural modifications.
3Ease of operation
If the connection housing is made large to accommodate the valve, then the installation is easier, but the flow resistance increases
Solution Approach 1:
The valve device is designed as a compact modular unit that can be installed into the connection housing without requiring the housing to be excessively large. The segmented design allows for efficient space utilization, maintaining low flow resistance while providing adequate installation access through the modular interface.
4Device complexity
If the flap device is designed as an integrated unit, then the assembly is simple, but the adaptability to different connection housings is reduced
Solution Approach 1:
The valve device incorporates universal mounting features and standardized interfaces that enable it to be adapted to different connection housing configurations. The modular design with standardized connection interfaces provides multi-functionality, allowing the same valve body to be installed in various housing types while maintaining assembly simplicity.
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 achieves a high degree of tightness and reduced flow resistance by minimizing leakages and allowing for precise adaptation of valve seat surfaces, enabling efficient gas flow management with minimal assembly complexity.
Implementation Method 1
Due to the flexible sealing element, slight unevenness can be compensated for by deformation.
Data Source
Figure 1
Figure 2~3
AI summary
These are flap devices for internal combustion engines with a flap housing (10) in which an inlet (22) and two outlets (24, 26) are formed, and a flap body (44) which has two flap halves (64, 66) and which is arranged on a shaft (42) which is rotatably mounted in the flap housing (10) and from which the two flap halves (64, 66) extend on both sides, wherein a first stop (48) and a second stop (52) are formed in the flap housing (10), against which, in a first end position of the flap body (44), one flap half (64; 66) of the flap body (44) abuts, and a third stop (50) and a fourth stop (54) are formed, against which, in a second end position of the flap body (44), one flap half (64; 66) of the flap body abuts (44) is known.To improve the sealing in the end positions, it is proposed according to the invention that the flap halves (64, 66) in their two end positions each rest with their entire outer circumference (67) perpendicularly on valve seat surfaces (56, 58, 60, 62) which are formed at the stops (48, 50, 52, 54) and that the flap halves (64, 66) extend in the end positions substantially parallel to the valve seat surfaces (56, 58, 60, 62).