Split-Casing Plastic Motorized Valve for Direct Fluid Sensing
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Solution Overview
Problem
Existing solutions for instrumented motorized valves in industrial and automotive applications face challenges in integrating sensors close to the valve and fluid, particularly with plastic materials, due to complex shapes and high material shrinkage, leading to bulky and cumbersome solutions that are difficult to manufacture reliably.
Innovation Solution
The design involves a plastic valve body with two separate casings, one for the actuator and mechanical fastening elements, and another for sensor integration, using bi-injection molding for sealing and metal inserts for mechanical attachment, allowing sensors to be directly in contact with the fluid without significant weight gain, and using simple, conventional tools for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sensors are integrated into plastic valve bodies using conventional machining methods, then sensor mounting is achieved, but manufacturing complexity and cost increase significantly due to difficult machining of injected thermoplastics
Solution Approach 1:
The valve body is divided into two separate injection-molded parts (first and second valve body parts) that are assembled together. Sensor mounting interfaces are integrated directly into these molded parts, eliminating the need for post-machining operations on the plastic material while maintaining sensor integration capability.
Solution Approach 2:
The sensor mounting interfaces are merged with the valve body structure itself during the injection molding process. The interfaces are formed as integral features of the molded parts, combining the valve body function with sensor mounting capability without requiring separate components or complex assembly steps.
2Ease of manufacture
If thick metal ducts are used to attach sensors to the valve, then sensor mounting is achieved, but the overall weight and bulk of the valve assembly increase
Solution Approach 1:
The heavy metal duct component is extracted from the design and replaced with thin-walled plastic valve body parts that are injection-molded with integrated sensor mounting interfaces. This eliminates the need for thick metal structures while maintaining the sensor attachment function.
Solution Approach 2:
The material parameter is changed from thick metal to thin-walled plastic, and the manufacturing method is changed from machining/metalworking to injection molding. This parameter change maintains structural integrity for sensor mounting while dramatically reducing weight and bulk.
3Shape
If complex injection molds with many movements are used to produce plastic valves with sensor interfaces, then valve shape complexity is achieved, but mold cost, reliability, and maintainability deteriorate
Solution Approach 1:
The valve body is segmented into two separately molded parts, each with simpler geometry that can be produced using straightforward injection molds. This segmentation allows each mold to be simpler while the final assembled valve achieves the required complex shape through the combination of the two parts.
Solution Approach 2:
The two-valve-body-part structure serves multiple functions: it achieves complex overall valve geometry, provides integrated sensor mounting interfaces in both parts, facilitates assembly, and enables the use of simpler, more reliable injection molds compared to a single complex molded part.
Data Source
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AI summary
The invention concerns an instrumented motorised valve (200) comprising a valve body made from plastic material, said valve body forming a conduit (202), said valve comprising an actuator (201) capable of moving a sealing element (205) in said conduit, said valve body also incorporating interfaces (215, 216) for attaching system state sensors, said state sensors being in direct contact with the fluid flowing in said conduit, said valve body also incorporating mechanical attachment elements (217a/204a, 217b/204b, 217c/204c) for attachment to the application. The valve body is made from two separate matching casings (211, 213), of which a first casing (211) comprises said actuator (201), said sealing element (205), said mechanical attachment elements (217a-c) for attaching said motorised valve to the application, and a part (223) of the interface (215) for attaching at least one of the system state sensors, and of which a second casing (213) comprises said mechanical attachment elements (204a-c) for attaching said motorised valve (200) to the application and the remainder of the interfaces for attaching the system state sensors. The conduit (202) is in two separate parts (218, 219), each respectively belonging to the first casing (211) and to the second casing (213).