Integrated Poppet Valve Spring Assembly Buckling Prevention
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Solution Overview
Problem
Existing pump sprayer discharge valve assemblies have a high part count due to separate valve and coil spring components, leading to manufacturing complexities and potential spring buckling issues, while integrated designs face challenges in repeatable throw and ease of manufacturing.
Innovation Solution
An integrated poppet valve, spring, and volume reducer with an omega-shaped spring design that is easy to manufacture and stable, reducing the risk of buckling, and allowing for a two-stage pressure build-up discharge valve assembly with a reduced priming volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate valve and coil spring components are used in the discharge valve assembly, then the valve function can be achieved, but the part count increases and manufacturing complexity increases
Solution Approach 1:
The patent combines the valve, spring, and piston into a single integrally molded component. The poppet valve is formed as an integral part of the piston body, and the compression spring is molded directly into the piston structure, eliminating the need for separate valve and spring components while maintaining all necessary functions.
2Ease of manufacture
If standard wave-shaped compression springs are used in integrated designs, then manufacturing is simplified, but the springs are subject to buckling
Solution Approach 1:
The patent employs an omega-shaped spring design with curved geometry that provides inherent structural stability. The omega configuration with its characteristic curves and loops resists buckling forces while maintaining compressibility, offering a balance between ease of molding and mechanical stability within the integrated piston structure.
3Reliability
If double helix spring designs are used in integrated valve assemblies, then spring stability is improved, but manufacturing difficulty increases
Solution Approach 1:
The omega-shaped spring provides sufficient stability with a simpler single-helix-like structure that is easier to mold than double helix designs. The curved omega geometry achieves the necessary structural integrity through its characteristic shape rather than requiring complex multi-helix configurations.
4Length of moving object
If the spring has a large compression capacity, then it can accommodate valve travel, but it cannot provide limited repeatable throw required for consistent spray
Solution Approach 1:
The patent modifies the spring's geometric parameters, specifically using the omega-shape with controlled compression characteristics. The spring is designed with a compression capacity of approximately 0.020 inches, providing limited repeatable throw that ensures consistent valve operation and uniform spray pattern while accommodating necessary valve travel.
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 integrated design reduces the number of components, prevents spring buckling, and maintains a uniform, repeatable mist spray by ensuring the valve opens and closes promptly at both the beginning and end of the pumping stroke, eliminating large droplets and achieving a narrow particle size distribution.
Implementation Method 1
a compression spring positioned in said valve chamber between said discharge passage and said poppet valve and in communication with said poppet valve to urge said poppet valve onto said valve seat into a closed position
Implementation Method 2
The valve opens in response to fluid pressure in the discharge passage which exceeds the closing force of the spring
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A sprayer includes a discharge valve assembly and includes an integrated poppet valve, spring and volume reducer. The spring includes more than omega-shaped form, each with relatively flat sides. The spring can have sides with portions sufficiently wide to substantially extend across the valve chamber to provide stability to the spring and prevent buckling. The flat sided omega-form construct is relatively easy to manufacture via molding and the ends of such construction provide suitable locations for integrated molding with the valve and the volume reducer.