Preassembled Valve Insert for Camshaft Adjuster Assembly
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Solution Overview
Problem
The existing construction of control valves for camshaft adjusters in internal combustion engines is complex and costly due to the separate installation of non-return valves and filters, which increases handling costs and processing steps during assembly.
Innovation Solution
A preassembled valve insert that integrates a filter and non-return valve with a closing element and seating element, forming a non-detachable structural unit that simplifies installation and reduces the risk of component detachment during operation, featuring a flat closing element and a seating element with a spring-like geometry for fluid-tight closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-return valves and filters are installed separately in control valves, then the valve can perform its function, but the assembly process becomes complex and handling costs increase
Solution Approach 1:
The patent combines the non-return valve and filter into a single integrated valve insert component. The non-return valve is formed as an integral part of the valve insert housing, with the filter element positioned within the same housing structure. This merging eliminates the need for separate installation of these components, simplifying the assembly process while maintaining the necessary functional complexity.
2Reliability
If separate components are used for non-return valve and filter, then each component can be optimized independently, but the risk of component detachment during operation increases
Solution Approach 1:
By integrating the non-return valve and filter into a single valve insert assembly, the patent eliminates the interfaces between separate components that could potentially detach. The non-return valve is formed as an integral part of the insert housing, creating a unified structure that reduces the risk of component detachment during operation while maintaining the functional benefits of having both components.
3Ease of operation
If multiple separate components are installed in the valve, then the valve can handle complex fluid control requirements, but handling costs and processing steps increase
Solution Approach 1:
The patent merges the non-return valve and filter into a single pre-assembled valve insert that can be installed as one unit. This integration reduces the number of handling operations required during assembly, as the entire assembly is installed in a single step rather than requiring separate installation of multiple components, thereby reducing handling costs and improving assembly productivity.
4Ease of operation
If a preassembled structural unit is used, then installation is simplified and handling costs are reduced, but the initial manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling the non-return valve and filter into the valve insert housing before the final valve assembly. The non-return valve is formed integrally with the insert housing, and the filter element is positioned within the housing during the insert manufacturing process. This preliminary assembly simplifies the final installation process, as the entire functional unit is ready for direct installation into the valve body.
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 preassembled valve insert simplifies the assembly process, reduces handling costs, and minimizes the risk of component detachment, providing a more economical and reliable solution for controlling pressurized medium flows in camshaft adjusters.
Implementation Method 1
The closing element has a closing geometry that closes a valve opening
Implementation Method 2
a central closing part spring-mounted by means of multiple spring tabs is shaped for closing a valve opening
Implementation Method 3
A ring filter is also installed in the pressurized medium line upstream of the non-return valve
Data Source
AI summary
A valve insert (8a, 8b) for a valve, in particular for a control valve (2) for controlling pressure-medium streams of a camshaft adjuster, includes an insert housing (10), in which a filter (12) and a non-return valve (14) with a closing element (24) and a seat element (20) are integrated. A configuration of the valve insert which is easy to install is ensured by at least the insert housing (10), the filter (12) and the seat element (20) being connected non-detachably to one another and forming one preassembled structural unit (40).