Hydraulic Control Valve Composite Bridge Design
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Solution Overview
Problem
Conventional hydraulic control valves face challenges with reduced hydraulic fluid flow due to excess composite material, leading to increased weight, manufacturing, and packaging costs, as well as longer manufacturing times.
Innovation Solution
A control valve design featuring a metal insert with a composite valve body and a connecting bridge defining a central angle between 5 and 45 degrees, which enhances fluid flow, reduces weight, and decreases manufacturing and packaging costs by optimizing the flow area and design complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite material is used between the first and second protrusions and between each of the fluid ports to provide sufficient support and strength for the composite valve body, then the structural strength is improved, but the flow area defined by the plurality of fluid ports is reduced, which decreases the amount of hydraulic fluid that flows into and out of the fluid passage
Solution Approach 1:
The patent applies local quality by positioning composite material only in specific locations where structural support is needed (between protrusions for strength) while deliberately excluding it from critical flow areas (between fluid ports). This localized material distribution allows the valve body to maintain sufficient strength without obstructing hydraulic fluid flow through the fluid ports.
2Strength
If composite material is used to ensure sufficient support and strength for the composite valve body, then the structural integrity is improved, but the weight of the control valve increases
Solution Approach 1:
The patent reduces weight by applying composite material only where structurally necessary (between protrusions) rather than throughout the entire valve body. This selective material placement maintains structural integrity in critical areas while minimizing overall weight by eliminating excess composite material in non-critical regions.
3Strength
If composite material is used to provide support for the composite valve body, then the manufacturing process becomes more complex, but the structural support is improved
Solution Approach 1:
The patent simplifies manufacturing by defining a specific geometric pattern for composite material placement (between protrusions only) rather than requiring complex molds or multi-step processes. This localized approach allows for simpler injection molding or material deposition processes while still providing the necessary structural support.
4Strength
If composite material is used between the first and second protrusions and fluid ports, then the structural strength is improved, but the manufacturing time increases
Solution Approach 1:
The patent reduces manufacturing time by limiting composite material application to specific regions (between protrusions) rather than requiring full coverage throughout the valve body. This localized material placement can be achieved more quickly through injection molding or other forming processes, reducing cycle time while maintaining necessary structural strength.
Data Source
AI summary
A control valve includes a metal insert extending along an axis and presenting an interior insert surface defining a fluid passage. The control valve also includes a valve member slidably disposed in the fluid passage, and a composite valve body. The composite valve body has a first and second protrusion disposed about the axis. The first protrusion is spaced from the second protrusion along the axis. The composite valve body has a connecting bridge integral with and extending between the first and second protrusions. The connecting bridge has a first connecting side and a second connecting side spaced from the first connecting side, with the axis, the first connecting side, and the second connecting side defining a central angle between 5 and 45 degrees.