Monolithic Pressure Regulator With Vesicle Wall for Compact Reliability
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Solution Overview
Problem
Pressure regulators in aircraft evacuation systems are prone to damage due to high packing density and multiple failure points, which can compromise their reliability and efficiency in emergency situations.
Innovation Solution
A monolithic pressure regulator design featuring a compact structure with fewer parts, including a body with a base wall, end wall, and side wall, and a cavity with a first vesicle that regulates fluid pressure from a source pressure to a regulated pressure, utilizing a sinusoidal, triangular, trapezoidal, sine-dwell, rectangular, or elliptical vesicle wall configuration to minimize parts count and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pressure regulators with multiple seals and moving subassemblies are used, then pressure regulation function is achieved, but the number of failure points increases and reliability decreases
Solution Approach 1:
The patent integrates multiple traditional regulator components (seals, springs, valves, housing) into a single monolithic structure formed by additive manufacturing. This merging of parts eliminates interfaces between components, removing potential failure points while maintaining pressure regulation functionality through the integrated design of the vesicle, bulkhead, and valve assembly.
Solution Approach 2:
The monolithic regulator is functionally segmented into distinct regions (input port region, cavity, output port region, vesicle, bulkhead) that can be independently designed and analyzed, even though they are manufactured as a single integrated part. This functional segmentation allows complex pressure regulation to be achieved through coordinated action of distributed functional zones within the monolithic structure.
2Volume of moving object
If high packing density is used to store the regulator with the evacuation slide in limited aircraft space, then space utilization improves, but the regulator becomes vulnerable to damage
Solution Approach 1:
By combining the regulator body, sealing elements, spring mechanism, and valve components into a single monolithic part, the patent eliminates internal interfaces that would be vulnerable to damage in high-density packing. The integrated structure distributes mechanical loads throughout the entire component rather than concentrating stresses at interfaces between separate parts.
Solution Approach 2:
The additive manufacturing process enables complex geometric parameters (such as the sinusoidal vesicle wall configuration) that optimize both the compact envelope and structural strength. The vesicle wall geometry can be tuned to provide structural rigidity while maintaining a compact form factor suitable for high-density packing.
3Volume of moving object
If a compact monolithic structure is used to reduce packing space, then storage volume decreases, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical assembly processes (joining multiple parts through fastening, sealing, and fitting) with additive manufacturing technology. This substitution allows the complex monolithic geometry to be manufactured in a single process without requiring assembly of multiple components, actually simplifying the overall manufacturing workflow despite the geometric complexity.
Solution Approach 2:
The sinusoidal vesicle wall configuration and other curved geometric features are naturally accommodated by additive manufacturing processes, which can create complex three-dimensional geometries without the tooling constraints of traditional manufacturing. The curved surfaces optimize space utilization while being easily fabricated through layer-by-layer deposition.
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 monolithic pressure regulator reduces the risk of damage and increases reliability by occupying less storage space and having fewer failure points, while maintaining the ability to effectively inflate evacuation devices during emergencies.
Implementation Method 1
a first vesicle configured to regulate a flow of fluid through the input port into the cavity at a source pressure to exit through the output port at a regulated pressure
Data Source
AI summary
A monolithic pressure regulator may comprise a boding comprising a base wall, an end wall, and a side wall, a cavity within the body, an input port in fluid communication with the cavity, an output port in fluid communication with the cavity, a first vesicle configured to regulate a flow of fluid through the input port into the cavity at a source pressure to exit through the output port at a regulated pressure, wherein the first vesicle comprises a first vesicle wall contiguous with a bulkhead and at least one of the base wall or the end wall.