Forged Fluid Control Valve with Angled Flow Channels
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Solution Overview
Problem
Existing fluid control valves face issues with leakage and limited controllability due to porous casted valve bodies and the mechanical limitations of forged valve bodies, while also being costly to manufacture.
Innovation Solution
A fluid control valve design featuring a forged valve body with angled flow channels formed by impression of kernels, allowing for cost-efficient production and improved controllability, with aligned outer connection openings facilitating machining and installation, and utilizing sealing members for reliable sealing without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a casted valve body is used, then the manufacturing cost is reduced, but the valve body becomes porous and may have cracks resulting in leakage
Solution Approach 1:
The patent changes the manufacturing method from casting to forging, which fundamentally alters the material structure and density of the valve body. Forging produces a denser, non-porous structure that eliminates leakage issues while maintaining cost-effectiveness through the specific kernel retraction technique.
2Reliability
If a forged valve body is used, then leakage is prevented, but the controllability of the control valve is limited
Solution Approach 1:
The patent segments the valve body formation process into distinct stages: initial forging with kernels, kernel retraction to create flow channels, and subsequent machining. This segmentation allows the forged valve body to maintain its structural integrity and leak-proof properties while enabling the creation of optimized flow channels that improve controllability.
Solution Approach 2:
The patent introduces angled flow channels (at 45 degrees to the valve center axis) as a dimensional variation that enhances fluid control. This angular configuration allows the valve member to effectively modulate flow while maintaining the benefits of the forged structure, thereby improving controllability without compromising reliability.
3Ease of manufacture
If the outer connection openings are aligned on a common axis, then machining and installation are facilitated, but the inner openings may become small causing high pressure drop
Solution Approach 1:
The patent resolves this contradiction by introducing a third dimension - angling the flow channels at 45 degrees to the valve center axis. This angular configuration allows the inner openings to remain large for low pressure drop while the outer connections remain aligned on a common axis for easy machining and installation. The angled path accommodates both requirements simultaneously.
4Reliability
If additional sealing components are added, then sealing reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the sealing function into the valve member itself by integrating sealing elements directly onto the valve member structure. This integration provides reliable sealing while avoiding the addition of separate sealing components, thereby maintaining device simplicity. The sealing function is combined with the flow control function in a single integrated component.
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The present invention relates to a fluid control valve comprising a valve body (3) with a valve chamber (5) extending along a valve centre axis (7), and a valve member (27) which is arranged in the valve chamber (5) for controlling at least a first flow of fluid through the control valve. The valve body (3) comprises a first flow channel (9) having an inner opening (19) fluidly connected to the valve chamber (5) and an outer connection opening (21) and extending along a first flow channel axis (11) being angled with respect to the valve centre axis (7), and a second flow channel (13) having an inner opening (23) fluidly connected to the valve chamber (5) and an outer connection opening (25) and extending along a second flow channel axis (15) being parallel to and offset from the first flow channel axis (11). The outer opening (21) of the first flow channel (9) and the outer opening (25) of the second flow channel (13) are aligned along a common axis (24). At least a part of at least one (9) of the first (9) and second (13) flow channels is formed by an impression of a kernel retracted along a respective flow channel axis (11).