Monolithic Valve Housing With Direct Spool Sliding to Cut Leakage
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Solution Overview
Problem
Existing solenoid valve systems face limitations due to the need for multiple valve housings on a single manifold, lack of adaptability, and the requirement for intermediate sleeves to prevent galling and scratching, which increases complexity and cost.
Innovation Solution
A monolithic combination manifold and valve housing made by additive manufacturing, where the valve spool is directly slidably mounted without an intermediate sleeve, using hardened 440C stainless steel for the valve spool and a different material for the remainder of the housing, with integrally formed connectors for self-locking and fluid passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an intermediate sleeve is used to prevent galling and scratching between the valve spool and valve housing, then the reliability of the valve is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the intermediate sleeve from the valve assembly, eliminating the need for this separate component that caused galling and scratching issues. The valve spool is made directly from softer material (aluminum or aluminum alloy) that can slide directly in the valve housing without causing damage, extracting the problematic intermediate component from the system.
Solution Approach 2:
The patent changes the material parameter of the valve spool from hardened steel to softer aluminum or aluminum alloy. This material parameter change eliminates the galling and scratching problems that occurred with harder materials, allowing direct contact between the valve spool and valve housing without an intermediate sleeve.
2Adaptability or versatility
If multiple valve housings are mounted on a single manifold housing, then the adaptability is improved, but the device complexity increases due to additional fasteners and seals
Solution Approach 1:
The patent integrates the manifold housing and valve housing into a single monolithic structure formed by additive manufacturing. This merging eliminates the need for separate fasteners, seals, and gaskets that were required when multiple valve housings were mounted on a manifold, reducing assembly complexity while maintaining the ability to configure different numbers of valves.
Solution Approach 2:
The additive manufacturing process enables the manifold-valve assembly to be configured with different numbers of valves (2, 3, 4, or more) using the same basic design platform. The universal design allows flexible adaptation to different application requirements without requiring completely different hardware configurations.
3Duration of action of stationary object
If hardened 440C stainless steel is used for the valve spool, then the durability is improved, but the manufacturing cost and complexity increase due to expensive machining requirements
Solution Approach 1:
The patent changes the material parameter of the valve spool from hardened 440C stainless steel to softer aluminum or aluminum alloy. This material substitution dramatically reduces manufacturing complexity and cost while maintaining sufficient durability for the application, as the softer material can be easily machined and formed using additive manufacturing processes.
Solution Approach 2:
The patent replaces traditional subtractive machining processes with additive manufacturing for producing the valve spool. This substitution eliminates the need for expensive and complex machining operations required for hardened steel, allowing cost-effective production of aluminum valve spools with the same geometric precision.
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
This solution reduces the number of parts, eliminates the need for fasteners and seals, and allows for a more compact, durable, and cost-effective assembly with improved structural integrity and reduced leakage rates, enabling flexible expansion of manifold banks without disturbing existing housings.
Implementation Method 1
The valve spool is finished to slidably fit within a valve hole and to slide virtually frictionless by floating on a thin air cushion as it reciprocates within the valve hole.
Data Source
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AI summary
A valve assembly has a valve housing with a hole therein. A valve spool is slidably received directly into the hole of the valve housing with no sleeves or seals interposed therebetween. Preferably, the valve housing and valve spool may be made from hardened stainless steel, preferably hardened 440C stainless steel. Preferably a combination modular housing has an integrally formed manifold section and valve section made by additive manufacturing.