Fluidizing Butterfly Valve Pneumatic Disk for Powder Flow
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Solution Overview
Problem
Existing valve technologies, such as sliding gate and butterfly valves, face challenges when handling fine powders, including leakage, contamination, high costs, large size, slow operation, and material retention, particularly when handling cohesive powders.
Innovation Solution
A fluidizing butterfly valve with a rotatable disk and shaft, equipped with a fluidizing membrane or plate that uses pressurized air or gas to fluidize materials above and below the disk, facilitating easy opening and maintaining flow without compacting the material, thus preventing blockages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a sliding gate valve is used for powder handling, then unobstructed flow channel is achieved, but metal-to-metal seat results in continuous powder trickling and leakage
Solution Approach 1:
The patent introduces an intermediary elastomeric seat material between the valve components, replacing the direct metal-to-metal contact. This elastomeric seat acts as a mediator that provides both sealing capability and flow control, eliminating the powder trickling issue while maintaining unobstructed flow when open.
Solution Approach 2:
The patent changes the material parameter of the seat from metal to elastomer, fundamentally altering the sealing mechanism. This material parameter change enables the seat to deform and conform to the valve body, providing reliable shutoff without the leakage problems of metal-to-metal seats.
2Reliability
If a sliding gate valve is used for corrosion resistance, then durability is improved, but valve size and weight increase making installation problematic
Solution Approach 1:
The patent extracts the corrosion resistance function from the entire valve body and concentrates it only where needed - specifically in the valve body and seat areas that contact the powder. This allows the use of corrosion-resistant materials only in critical zones, reducing overall valve weight while maintaining durability.
Solution Approach 2:
The patent applies corrosion-resistant materials locally to specific components (valve body, seat) rather than throughout the entire valve assembly. This localized application of corrosion resistance reduces the overall weight and material cost while maintaining protection where it is most needed.
3Quantity of substance
If sliding gate valve size is increased for larger flow capacity, then flow rate is improved, but valve operation speed decreases becoming very slow
Solution Approach 1:
The patent transitions from the static linear motion of sliding gate valves to dynamic rotary motion of butterfly valves. This dynamic rotation allows larger valves to operate more quickly, as the rotational inertia and mechanical advantage provide faster actuation speeds compared to linear sliding motion of equivalent size.
Solution Approach 2:
The patent inverts the traditional gate valve sliding motion and replaces it with rotary motion. This fundamental motion inversion allows the valve to achieve both large flow capacity and fast operation, as the rotary mechanism provides mechanical advantage and reduced friction compared to linear sliding.
4Speed
If sliding gate valve actuating cylinders are increased for faster operation, then speed is improved, but compressed air consumption increases significantly
Solution Approach 1:
The patent utilizes pneumatic actuation optimized for butterfly valve geometry, where compressed air is applied more efficiently to the smaller rotary actuator. This reduces the total air consumption compared to large linear cylinders, while still achieving fast operation through the mechanical advantage of the rotary mechanism.
Solution Approach 2:
The patent employs dynamic rotary actuation that requires less energy input than static linear actuation. The rotary motion allows for more efficient energy transfer and reduced air consumption, as the smaller actuator mass and shorter stroke reduce the work required to move the valve.
5Device complexity
If butterfly valve disk upward motion is used for opening, then compact structure is achieved, but material compression and packing increases likelihood of flow blockage
Solution Approach 1:
The patent applies preliminary action by introducing fluidizing air through the disk before the valve opens. This pre-fluidization prevents material compression and packing that would otherwise occur during the opening motion, ensuring smooth flow establishment without blockages.
Solution Approach 2:
The patent uses pneumatic fluidization through the valve disk to counteract the compressive effect of material on the disk. By introducing air flow through the disk, the material is kept in a fluidized state, preventing packing and blockage while maintaining the compact butterfly valve structure.
6Reliability
If butterfly valve elastomeric seat is used for shutoff, then sealing tightness is improved, but material retention in dead spots increases
Solution Approach 1:
The patent maintains continuous useful action by keeping the valve disk in a position that allows material flow even when closed. The elastomeric seat provides sealing while the disk geometry and fluidization prevent material accumulation in dead spots, ensuring continuous material movement and reducing retention.
Solution Approach 2:
The patent changes the material parameter of the seat to elastomer, which provides sealing while allowing for flow modulation without complete closure. This parameter change enables the valve to maintain tight sealing while minimizing dead spots where material could be retained, as the elastomeric seat can accommodate partial opening positions.
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 fluidizing butterfly valve ensures tight shutoff, reduces material retention, enhances flow efficiency, and minimizes waste, while being more compact and cost-effective compared to traditional valves, with minimal dead spots and effective sealing.
Implementation Method 1
a fluidizing membrane or plate that uses pressurized air or gas to fluidize materials above and below the disk
Data Source
AI summary
A fluidizing butterfly valve. The fluidizing butterfly valve includes a valve body and a fluidizing valve disk or member configured to fluidize material located above the butterfly valve and/or material moving through the butterfly valve.