Overlapping Flow Channels for Compact High-Flow Valve Blocks
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Solution Overview
Problem
Mass flow controllers face limitations in achieving higher flow rates while maintaining compactness, as the maximum flow rate is restricted by the capacity of control valves, making it difficult to reduce the size of the apparatus without compromising width.
Innovation Solution
The fluid control apparatus employs two control valves arranged in a longitudinal direction with overlapping outflow and inflow channels, allowing for a confluent line configuration that doubles the maximum flow rate without increasing the width, and includes a fluid controller for precise flow rate control and self-recovery functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two control valves are disposed side by side in the width direction to double the flow rate, then the maximum flow rate increases, but the width of the block increases making it difficult to reduce the size
Solution Approach 1:
The patent transitions from a two-dimensional side-by-side arrangement to a three-dimensional overlapping arrangement. The first outflow channel and second inflow channel are positioned to overlap when viewed in the width direction, allowing control valves to be stacked vertically rather than placed horizontally. This dimensional change enables doubled flow rate while maintaining compact width.
Solution Approach 2:
The patent implements a nested configuration where the second inflow channel is positioned within the spatial envelope of the first outflow channel. The channels are arranged concentrically or in overlapping patterns, allowing one channel to be nested within or alongside the other, thereby reducing the overall width requirement while accommodating both flow paths.
2Area of stationary object
If the block width is reduced to maintain compactness, then the apparatus size decreases, but it becomes difficult to dispose two control valves and their associated channels without interference
Solution Approach 1:
By utilizing the vertical dimension and overlapping the channels in the width direction, the patent reduces the horizontal space requirement. The channels are routed in three dimensions rather than confined to a single plane, allowing compact width while avoiding interference through vertical separation and overlapping projection.
Solution Approach 2:
The patent divides the flow path into distinct segmented channels (first inflow, first outflow, second inflow, second outflow) with clearly defined spatial relationships. Each channel is independently routed and positioned, allowing precise control of their overlapping arrangement without interference, thereby managing complexity through systematic segmentation.
3Speed
If control valves are mounted on a protrusion to reduce internal flow channel length, then control responsiveness improves, but the device complexity increases
Solution Approach 1:
The patent extracts the second control valve from the main block body and positions it on a protrusion that extends outward. This separation reduces the length of internal flow channels within the block by placing the valve closer to the outlet, thereby improving control responsiveness while the protrusion structure manages the added complexity.
Data Source
AI summary
A fluid control apparatus includes a block elongated in a longitudinal direction and having a predetermined width, an internal flow channel formed inside the block so as to extend in the longitudinal direction, a first control valve mounted on the block, a second control valve mounted on the block at a position downstream of the first control valve. In the fluid control apparatus, the internal flow channel has a first outflow channel connected to a first outlet of the first control valve through which a fluid flows out thereof and also has a second inflow channel connected to a second inlet of the second control valve through which the fluid flows thereinto. In addition, the first outflow channel and the second inflow channel are disposed so as to overlap each other at one point as viewed in the width direction through the block.