Pneumatic Control Valve Integrated Casing and Stopper Guide
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Solution Overview
Problem
There is a demand for improving the performance, reducing the size, and enhancing the reliability and durability of conventional pneumatic control valves, while also reducing costs.
Innovation Solution
The pneumatic control valve integrates a valve body with a piston chamber and a diaphragm, using cylindrical stoppers to guide and fix the piston stem, eliminating the need for bolts and allowing for a more compact design by sequentially inserting and fixing components from the upper opening, with anti-rotation and anti-falling off features to prevent axial rotation and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pneumatic control valves use multiple bolts to integrate casing bodies, then leakage prevention is achieved, but the valve size and complexity increase
Solution Approach 1:
The patent integrates the valve body and actuator housing into a single integrated casing structure, eliminating the need for multiple separate casing bodies that would require bolts for assembly. This merging of components reduces the total number of parts while maintaining the sealing function through integrated design features
Solution Approach 2:
The patent removes the bolt assembly mechanism from the valve structure by designing an integrated casing that achieves leakage prevention through alternative means such as integrated sealing surfaces and monolithic construction, rather than relying on fastened joint interfaces
2Strength
If conventional pneumatic control valves use multiple bolts to integrate casing bodies, then structural strength is maintained, but manufacturing cost and assembly time increase
Solution Approach 1:
The integrated casing structure combines multiple structural elements into a single manufactured component, reducing the number of parts that need to be produced, inventoried, and assembled. This consolidation reduces manufacturing complexity and associated costs while maintaining structural integrity through the unified design
3Volume of moving object
If the valve structure is reduced in size, then apparatus size decreases, but reliability and durability of the diaphragm may be compromised
Solution Approach 1:
The patent applies local quality by providing enhanced support and guidance specifically at the diaphragm and piston stem regions through guide structures and support surfaces. This localized reinforcement ensures diaphragm reliability in the compact design without requiring overall enlargement of the valve structure
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 integration reduces the number of components and manufacturing steps, enhancing reliability and durability, allowing for smaller apparatuses with improved performance and lower costs.
Implementation Method 1
a diaphragm that is provided so as to separate the valve chamber in which a fluid flows and an opening/closing mechanism in a liquid-tight manner
Implementation Method 2
a pneumatic control valve (pneumatic on-off valve) that is provided with an actuator operated by pneumatic pressure so as to enable remote operation
Implementation Method 3
a spring member that upwardly urges the valve element so as to hold a fully open position
Data Source
AI summary
To provide a pneumatic control valve including: a valve body 10; a valve opening/closing mechanism section 20; a pneumatic control section 60 for the valve opening/closing mechanism 20 that is coupled to the valve element 21 via a piston stem 62; a diaphragm 30 that defines a partition between a fluid and the pneumatic control section 60; a cylindrical lower stopper 40 that is fixed to the valve body 10 as anti-falling off for the valve element 21 and the diaphragm 30 inserted into a valve chamber 13, and supports movement of the piston stem 62; and a cylindrical upper stopper 50 that is fixed to the valve body 10 as anti-falling off for the piston stem 62 inserted into a piston chamber 15, and supports movement of the piston stem 62.