Integrated Orifice Mixing Valve for Precise Low-Flow Fluid Ratios
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Solution Overview
Problem
Existing fluid mixing devices are complex, bulky, costly, prone to assembly errors, and require frequent calibrations due to their multi-component nature, which makes them unreliable and difficult to fit in tight spaces, especially when precise adjustments for small gas amounts are needed.
Innovation Solution
A compact control valve with integrated first and second housing orifices and check valves that allow precise mixing of fluids by varying the orifice sizes to achieve desired mixture ratios without the need for complex assembly or active monitoring, featuring replaceable orifice members for adaptability across multiple applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple separate components (valves, fittings, manifold, hoses) are used to assemble a fluid mixing device, then the device can achieve fluid mixing function, but the device becomes complex, bulky, and costly with frequent assembly errors and leaks
Solution Approach 1:
The patent merges multiple separate components (inlet valves, check valves, mixing chamber, outlet valve, fittings, and hoses) into a single integrated housing structure. The first and second inlet ports with their respective check valves and the outlet port are all incorporated into one unified device, eliminating the need for separate fittings, manifold, and hoses. This integration directly reduces device complexity while improving reliability by eliminating multiple connection points where leaks and assembly errors could occur.
2Measurement precision
If ball or needle valves are used to adjust fluid flow for mixing, then the device can control mixing ratio, but the device requires frequent adjustments and calibrations and is not precise enough for small gas amounts
Solution Approach 1:
The patent changes the flow control parameter from adjustable valve openings (ball or needle valves) to fixed orifice sizes. By providing multiple inlet ports with different fixed orifice dimensions, the device achieves precise mixing ratios through the inherent flow characteristics of the orifices rather than requiring frequent manual adjustments. This approach provides better precision for small gas amounts while simplifying operation, as the mixing ratio is determined by the fixed geometric parameters of the orifices rather than requiring continuous valve adjustment.
3Volume of moving object
If a compact design is implemented to fit tight spaces, then the device can be installed in small environments, but the device may lack the necessary components for precise mixing control
Solution Approach 1:
The patent provides a universal mixing device that can handle multiple fluid types (gas-gas, gas-liquid, liquid-liquid mixing) through a single integrated housing design. The first and second inlet ports can receive different fluid inputs, and the check valves are configured to work with various fluid combinations. This multi-functional design achieves adaptability across different applications while maintaining a compact form factor, as all necessary components are integrated into the single housing rather than requiring separate devices for different mixing scenarios.
4Ease of manufacture
If multiple separate components are assembled into a mixing device, then the device can be assembled, but the assembly process is time-consuming and costly with potential assembly errors
Solution Approach 1:
The patent combines multiple components that would traditionally be assembled separately (inlet valves, check valves, mixing chamber, outlet valve, and fittings) into a single molded housing. This integration eliminates the need for time-consuming assembly of multiple parts and reduces manufacturing complexity. The single housing can be produced more efficiently through molding processes, significantly reducing assembly time and the potential for assembly errors while lowering manufacturing costs.
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 solution provides a precise mixture ratio with reduced likelihood of leaks and assembly errors, is compact enough for small environments, and can be adapted into existing systems, offering simplicity and cost-effectiveness while supporting multiple fluid mixing applications.
Implementation Method 1
The first inlet port may be configured to receive the first check valve that allows the first inlet fluid to pass from the first inlet port, through the first fixed inlet orifice and to the mixture chamber and prevents backflow from the mixture chamber back to the first inlet port
Implementation Method 2
a first inlet port orifice member configured with a first inlet port orifice with a first inlet port orifice size to provide a first inlet fluid with a first inlet volumetric flow rate
Data Source
AI summary
A control valve features a first housing and a second housing. The first housing includes a first inlet port having a first inlet port orifice member with a first inlet port orifice size configured to provide a first inlet fluid with a first inlet volumetric flow rate, the first inlet port orifice member being detachably coupled inside the first inlet port; includes a second inlet port having a second inlet port orifice member with a second inlet port orifice size configured to provide a second inlet fluid with a second inlet volumetric flow rate, the second inlet port orifice member being detachably coupled inside the second inlet port; and includes a first housing rim configured to extend from the first fixed inlet and the second fixed inlet. The second housing includes a second housing rim coupled to the first housing rim and configured to form a mixture chamber to mix the first inlet fluid received from the first fixed inlet orifice and the second inlet fluid received from the second fixed inlet orifice and provide a mixture chamber fluid; and an outlet port having an outlet port orifice with an outlet port orifice size configured to provide the mixture chamber fluid as an outlet port fluid having an outlet volumetric flow rate. The outlet port fluid has a mixture ratio of the first inlet fluid and the second inlet fluid for a particular application that depends on dimensions of the first inlet port orifice size, the second inlet port orifice size and the outlet port orifice size.