Pre-chamber Gas Valve Pressed Plug Centering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pre-chamber gas valves in internal combustion engines require complex and costly production steps due to the use of concentric sleeve-shaped components for centering, which complicates the manufacturing process and assembly.
Innovation Solution
A pre-chamber gas valve with a pressed plug closing the space containing the valve spring, where a cap connected to the valve needle provides bracing and guidance, allowing for a one-piece valve body that simplifies production and enhances durability, and a pear-shaped space configuration for improved fluid guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concentric sleeve-shaped components are used to close the upper cavity, then the valve structure is sealed, but the production process becomes complicated and expensive due to centering steps
Solution Approach 1:
The patent merges the closure function and the centering function into a single pressed plug component. The pressed plug is designed with a geometry that automatically centers itself in the upper cavity during pressing, eliminating the need for separate centering steps or multiple sleeve components. This single-component solution maintains sealing reliability while dramatically simplifying the manufacturing process.
Solution Approach 2:
The pressed plug incorporates self-centering features through its geometric design, where the plug's shape and the cavity's geometry work together to automatically position the plug correctly during the pressing operation. The plug serves its own centering function without requiring external centering mechanisms or additional processing steps, thereby reducing production complexity.
2Ease of manufacture
If a one-piece valve body is used, then manufacturing is simplified and robustness is enhanced, but assembly of internal components becomes more difficult
Solution Approach 1:
The patent segments the valve into distinct functional components (valve body, pressed plug, cap, valve needle, spring) that can be manufactured separately and then assembled. The one-piece valve body is designed with built-in features like the upper cavity and seating surfaces that guide the assembly of internal components, making the assembly process manageable despite the integrated body structure.
Solution Approach 2:
The one-piece valve body performs multiple functions: it provides structural support, creates the upper cavity for the spring, provides seating surfaces for the valve needle, and guides the assembly of internal components. This multi-functionality reduces the overall number of parts needed while maintaining assembly feasibility through intelligent design of the integrated body.
3Manufacturing precision
If the cap bears against the valve body in the opened condition, then the valve needle movement has a well-defined end position, but the structure requires precise geometric configuration
Solution Approach 1:
The cap is designed with a predetermined geometric configuration that establishes the correct end position for the valve needle before the valve operates. The shouldered configuration of the cap creates a mechanical stop that limits the valve needle's travel, ensuring precise positioning is built into the structure from the beginning rather than requiring adjustment during operation.
Solution Approach 2:
The cap features an asymmetric shouldered configuration with different diameters creating distinct positioning zones. This asymmetric geometry provides a unique mechanical interface that ensures the valve needle achieves a well-defined end position in the opened condition, while the asymmetric features are intentionally designed to simplify manufacturing rather than complicate it.
Data Source
AI summary
A pre-chamber gas valve including a valve body, at least one valve spring and at least one valve needle, wherein the valve body has a lower space which is acted upon with gas in the operating condition and an upper space in which the valve spring is arranged, wherein the upper space is closed by way of a pressed plug.