Expansion valve
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Solution Overview
Problem
Existing expansion valves are complex, prone to high wear, and difficult to replace, with complicated configurations that lead to frequent replacement and increased manufacturing costs.
Innovation Solution
A compact expansion valve design utilizing a stepper motor, a hollow shaft, a center spool, and a spiral body with a sliding ring, which allows for axial movement and simplified configuration, reducing wear and facilitating easy replacement, while also incorporating pressure balancing channels for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complicated stopper structure with multiple components (stopper, engagement element, annular support pin) is used to define end points for valve opening and dosing, then the valve can perform its function, but the device complexity increases and replacement becomes difficult
Solution Approach 1:
The patent extracts the stopper function from a complex multi-component structure and integrates it into a simplified single-component design. The stopper is now a simple axial component that works with the threaded connection to define end positions, eliminating the need for engagement elements and annular support pins. This extraction principle reduces device complexity while maintaining the essential function of defining valve opening and dosing end points.
Solution Approach 2:
The threaded connection serves multiple functions: it transposes rotational movement to axial movement for valve control, and simultaneously provides the stopper function by defining end positions through its geometric constraints. This multi-functionality eliminates the need for separate stopper mechanisms, reducing overall device complexity while maintaining reliable valve operation.
2Ease of operation
If a complex configuration with multiple components is used for the expansion valve, then the valve can be controlled, but the ease of manufacture decreases and fabrication becomes expensive
Solution Approach 1:
The patent merges multiple functions into fewer components. The threaded connection combines valve control actuation with positioning functions. The stopper is integrated as a simple axial component rather than a separate complex assembly. This merging reduces the number of parts that need to be manufactured and assembled, significantly improving ease of manufacture while maintaining full valve control functionality.
Solution Approach 2:
The valve is designed with modular segments that can be manufactured separately and assembled easily. The hollow shaft, spiral body, and valve components can be produced as independent units using standard manufacturing processes, then connected through simple interfaces. This segmentation allows each component to be optimized for its specific manufacturing process, reducing overall fabrication complexity and cost.
3Productivity
If traditional expansion valve designs are used, then the valve can operate, but wear increases and replacement frequency increases
Solution Approach 1:
The patent designs the valve with simple, easily replaceable components that can be quickly swapped out when worn. The modular design allows the valve core or seal components to be replaced without replacing the entire valve assembly. This approach accepts that wear-prone components will need replacement but minimizes the cost and time of replacement, effectively managing wear through easy maintainability rather than attempting to eliminate it entirely.
4Device complexity
If a compact design with fewer components is used, then replacement becomes easier and manufacturing is simpler, but pressure balancing between spaces becomes more difficult
Solution Approach 1:
The patent introduces pressure balancing channels as intermediary fluid pathways that connect different valve spaces. These channels allow pressure equalization between the inlet side and outlet side of the valve without requiring complex mechanical counterbalancing mechanisms. The fluid itself acts as the intermediary that transmits and equalizes pressure, maintaining reliability of pressure balancing while keeping the mechanical configuration simple and compact.
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 results in a compact, low-wear expansion valve with simplified replacement and reduced manufacturing complexity, achieving reliable pressure balancing and operational efficiency.
Implementation Method 1
a center spool that is arranged within the hollow shaft and drivable by the rotor so that a rotation of the spool is transferrable through a threaded connection into an axial movement for opening and closing the expansion valve
Implementation Method 2
a spiral body that includes a thread turn and that is arranged on an enveloping surface of the hollow shaft and drivable by the rotor, wherein a stop element is arranged at the hollow shaft and movable in the thread turn of the spiral body
Data Source
AI summary
An expansion valve operable by a stepper motor, the expansion valve including a housing; a hollow shaft arranged in the housing; a valve base that supports the hollow shaft and closes the housing; a rotor drivable by a stator of the stepper motor; a center spool arranged in the hollow shaft and drivable by the rotor so that a rotation of the center spool is transferrable by a threaded connection into an axial movement of the center spool that opens or closes the expansion valve; and a sleeve that includes a receiving portion that includes at least portions of the center spool, of a compression spring and of a force transmission element respectively and a valve needle, wherein the receiving portion of the sleeve element is closed by a bushing.