Segmented Multiport Valve Layout for Continuous Plastic Melt Switching
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Solution Overview
Problem
Existing multi-way valve units for plastic melts and high viscosity liquids require large installation spaces and are difficult to manufacture, with fluid flow interruptions during switching due to pressure peaks and complex designs.
Innovation Solution
A segment-shaped switching element with an offset pivot axis and flow-through recesses arranged radially, allowing for compact design and uninterrupted fluid flow by maintaining overlap between flow channel openings during switching, utilizing a hydraulic drive and clamping elements for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circular disk-shaped switching element is used, then reliable switching at high pressures and temperatures is achieved, but a large housing and installation space are required
Solution Approach 1:
The switching element is divided into multiple segments (typically three) that can rotate independently around a central axis. Each segment contains flow-through recesses that align with corresponding flow channels in the housing plates when positioned correctly. This segmentation allows the switching element to be more compact than a full circular disk while still providing the necessary flow control functions.
Solution Approach 2:
The patent transitions from a two-dimensional circular disk design to a three-dimensional segmental structure with radial arrangement. The flow-through recesses are positioned radially outward from the rotation axis, allowing the switching element to occupy less central space while maintaining effective flow control. This dimensional reorganization reduces the overall housing size required.
2Adaptability or versatility
If a circular disk-shaped switching element is used, then switching options between multiple connections are provided, but the housing size increases significantly
Solution Approach 1:
The circular disk is segmented into discrete rotational sections, each capable of aligning with different flow channel configurations. With three segments, the switching element can provide multiple switching positions (typically 3-6 positions depending on configuration) while occupying only a fraction of the space required by a full circular disk design.
Solution Approach 2:
The segmental switching element is designed to provide multiple switching functions within a single compact component. By rotating the segments to different angular positions, the same physical structure can connect different combinations of flow channels, providing versatile switching options without requiring additional components or increased housing size.
3Ease of manufacture
If the pivot axis is located at the edge of the switching element, then manufacturing is simplified, but the pressurized area increases and sealing becomes more difficult
Solution Approach 1:
The pivot axis is positioned asymmetrically within the switching element structure, specifically at the center rather than at the edge. This central positioning creates a more balanced distribution of pressurized areas around the rotation axis, reducing the maximum radial distance that sealing surfaces must cover. The asymmetric radial arrangement of flow-through recesses further optimizes the pressure distribution while maintaining sealing effectiveness.
4Adaptability or versatility
If flow-through recesses are arranged in a large circular pattern, then multiple flow channels are accommodated, but installation space requirements increase
Solution Approach 1:
The flow-through recesses are distributed across multiple segments rather than arranged in a single large circular pattern. This segmentation allows the same number of flow channels to be accommodated in a more compact radial arrangement, reducing the overall diameter of the switching element and the required housing size.
Solution Approach 2:
The patent utilizes radial positioning of flow-through recesses at optimized distances from the rotation axis, transitioning from a planar circular arrangement to a three-dimensional radial configuration. This allows multiple flow channels to be accessed within a smaller footprint by exploiting the radial dimension efficiently, reducing the housing area required while maintaining full flow channel connectivity.
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 enables efficient, uninterrupted fluid transfer with reduced space requirements and simplified manufacturing, maintaining over 80% flow channel cross-sectional area during switching, suitable for high viscosity fluids like plastic melts.
Implementation Method 1
connected to a drive, such as, in particular, a linear drive via a hydraulic cylinder
Implementation Method 2
the movable switching element is mounted between an inlet plate and an outlet plate, wherein the inlet and outlet plates are kept at a distance from each other by inserted intermediate plates and/or by other spacer elements
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The invention relates to a multiport valve unit (100) for medium- to high-viscosity fluids, said multiport valve unit having a housing comprising at least: - an inlet plate having at least one main flow channel (41); - an outlet plate having at least one main flow channel; and - at least one secondary flow channel (42); wherein at least one intermediate plate (13, 14) and/or at least one spacer element (15) are located between the inlet plate and the outlet plate. The multiport valve unit also has at least one switching element (20) mounted pivotably or rotatably in the housing (10), which switching element: - is located between the inlet plate and the outlet plate; - in a starting position, connects the main flow channels (41) to one another via at least one passage opening (22, 23); and - in at least one switching position, connects in each case at least one of the main flow channels (41) to the at least one secondary flow channel (42) via at least one deflection channel (24) which opens only to one side of the switching element (20); wherein - the switching element (20) is segment-shaped and is positioned adjacent to the intermediate plate (13, 14) and/or the at least one spacer element (15); - the mouth openings of the main flow channels (41), which mouth openings are provided in the inlet plate (11) and/or in the outlet plate (12) and face the switching element (20), and a mouth opening of the at least one secondary flow channel (42) are located on different partial circles (1, 2) with respect to a pivot axis (19) of the switching element (20); and - the deflection channel (24) extends on the switching element (20) between the partial circles (1, 2).