Metal Piston Valve Seal Structure for High-Temperature Cycling
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Solution Overview
Problem
Existing turbocharger thrust air valves with plastic pistons face challenges in maintaining sealing functionality over their lifetime due to high operational temperatures and lock cycles, leading to increased costs and decreased density, while requiring rapid opening and closing to prevent turbocharger braking.
Innovation Solution
A metal piston with a distinct sealing material, such as stainless steel and EPDM or PPA, is used, featuring annular recesses for improved sealing and production efficiency, along with a secure connection method like welding or riveting, allowing for enhanced temperature resistance and media resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic piston is used, then the production cost is reduced and the piston is lighter, but the sealing function deteriorates over lifetime due to high temperatures and operational cycles
Solution Approach 1:
The piston is divided into two separate components: a metal piston body and a separate sealing element. The sealing element is inserted into a recess in the piston bottom and retained by formation elements. This segmentation allows each component to be optimized independently - the metal piston for thermal resistance and structural integrity, and the sealing element for sealing performance under high temperatures and pressure cycles.
Solution Approach 2:
The valve combines different materials - a metal piston (steel or aluminum alloy) with a separate sealing element made of elastomer or plastic. This composite construction leverages the high temperature resistance and mechanical strength of metal while incorporating the excellent sealing properties of elastomers or plastics, resolving the contradiction between durability and sealing function.
2Ease of manufacture
If the piston structure is simplified for easy production, then manufacturing complexity is reduced, but sealing performance may be compromised
Solution Approach 1:
The sealing function is segmented from the piston body and implemented as a separate insertable element. The piston bottom includes a recess and formation elements (such as lugs or ribs) that simple retain the sealing element. This segmentation allows the piston body to be manufactured using simple deep-drawing processes while the sealing element can be separately manufactured and installed, maintaining both production simplicity and sealing performance.
3Speed
If rapid closing is achieved by applying piston to valve seat, then valve response speed is improved, but sealing durability deteriorates under high operational cycles
Solution Approach 1:
The sealing element is designed with specific local properties at the sealing surface - sufficient hardness to maintain sealing contact under rapid closing forces, yet sufficient elasticity to compensate for wear and dimensional variations over thousands of operational cycles. The formation elements providing retention are designed with appropriate geometry to secure the sealing element without interfering with its sealing function.
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 improved sealing functionality, reduced production complexity, and increased durability, enabling the valve to operate effectively at higher temperatures and maintain performance over its service life without significant weight increase.
Implementation Method 1
a solenoid arranged in the housing, a piston movable by the solenoid
Implementation Method 2
Due to the elasticity of the sealing material, the administrations may have a slightly larger cross-section than the recesses through which they pass through during assembly of the seal
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a valve having a housing (1), a solenoid (5) disposed in the housing (1), a pin (7) that can be moved by the solenoid, a piston (8) connected to the pin (7), and a seal. The piston (8) consists of a metal and has a seal (14) which consists of a material different from that of the piston (8), said seal (14) being arranged in the head region (12) of the piston (8).