Helical Composite Channel Valve for Linear Pressure Loss Control

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Solution Overview

Problem

Prior art valves lack a consistent and accurate linear relationship between differential pressure loss and active channel length, leading to instability and increased maintenance costs in industrial applications, particularly in HVAC systems and robotic control systems.

Innovation Solution

A differential pressure loss valve with a cylindrical hollow section and a channel carrier featuring a continuous cylindrical helical thread, where the channel carrier is movable within the sleeve to adjust the active channel length, forming a composite channel with a constant cross-section, allowing for precise control of differential pressure loss and achieving linearity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a prior art valve uses a curved channel section (e.g., 90 degree curvature), then the valve can achieve compact geometry, but the differential pressure loss increases 3 to 7 times compared to a straight channel of equal length

Engineering Contradiction:

Improvevalve compactnessVSAvoiddifferential pressure loss

Core Design Contradiction:

Volume of moving objectVSLoss of energy

Solution Approach 1:

The channel is divided into multiple straight sections connected by transition sections. Rather than using a single curved channel, the flow path is segmented into alternating straight and transition portions, reducing pressure loss while maintaining compact overall valve geometry through the alternating pattern.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The transition sections use optimized curvature radii (e.g., R1, R2, R3) to smoothly connect straight channel sections. The curvature is carefully controlled with specific radius ratios to minimize flow separation and pressure loss while achieving the necessary directional changes in the compact valve body.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Area of stationary object

If a prior art valve uses a smaller cross-sectional area channel, then the valve size is reduced, but the differential pressure loss increases significantly

Engineering Contradiction:

Improvevalve sizeVSAvoiddifferential pressure loss

Core Design Contradiction:

Area of stationary objectVSLoss of energy

Solution Approach 1:

The channel cross-sectional area is varied dynamically along the flow path. Larger cross-sectional areas are provided in straight sections where pressure loss is already minimized, while transition sections use optimized curvature. This dynamic variation maintains low pressure loss while keeping the overall valve compact.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Different sections of the channel have different cross-sectional areas optimized for their specific function. Straight sections have larger areas to minimize pressure loss, while transition sections have controlled curvature radii. This local optimization allows the valve to be compact overall without sacrificing pressure loss performance.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If a prior art valve has a non-linear gain characteristic, then the valve can achieve variable flow control, but stability is compromised in robotically controlled applications

Engineering Contradiction:

Improvevariable flow controlVSAvoidcontrol stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The valve geometry parameters (channel cross-sectional area, curvature radii, straight section lengths) are specifically designed and optimized to achieve a substantially linear gain characteristic. This linear relationship between valve position and differential pressure loss provides stable, predictable control for robotic applications while maintaining variable flow control capability.

Inventive Principle:

Principle #35Parameter changes

4Measurement precision

If a prior art valve requires electronic compensators to achieve linearity, then the valve can provide accurate control, but the device complexity and cost increase

Engineering Contradiction:

Improvecontrol accuracyVSAvoidvalve structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The valve geometry itself is designed to inherently provide the desired linear gain characteristic through optimized channel cross-sectional area distribution and transition section curvature. The valve structure serves its own linearization function, eliminating the need for external electronic compensators or complex control systems while maintaining accurate control.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11649909B2Differential pressure loss valve

Publication Date: 2023.05.16 FAICZAK JOHN

AI summary

The present invention is a differential pressure loss valve comprising a valve housing that incorporates: a sleeve that incorporates a continuous cylindrical helical thread formed in the inner surface thereof; and a cylindrical channel carrier incorporating a cylindrical helical thread formed in the outer surface thereof. When the channel carrier is positioned within the sleeve a portion of the sleeve cylindrical helical thread integrates with the channel carrier cylindrical helical thread, and a composite channel is formed there-between. The geometric configuration of the composite channel is consistent throughout such composite channel, although the geometric configuration may differ in individual embodiments of the present invention. Fluid can flow within the valve between an inlet port incorporated in the sleeve and an outlet port incorporated in the valve housing and through the composite channel, or any portion thereof between the inlet port and outlet port, if any.