Pressure-Balanced 2/2-Way Valve Sealing With Low-Friction Molded Elastomer
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Solution Overview
Problem
Pressure-balanced valves with abrasive seals, such as O-rings, experience rapid wear due to grinding movements, leading to increased friction losses, cycle time delays, and irreversible leaks, while membrane-based valves have complex assembly and maintenance issues and manufacturing defects.
Innovation Solution
A pressure-balanced 2/2-way valve design featuring a valve housing with an electromagnetic actuator and a spring-elastic restoring element, where the valve tappet head is coated with a materially bonded, non-abrasive elastomer forming a one-piece molded part with a radially circumferential separating ridge, minimizing mechanical friction and enabling easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sliding seals (O-rings) are used for sealing the valve chamber, then sealing function is achieved, but mechanical friction losses increase rapidly due to grinding movements
Solution Approach 1:
The patent replaces the traditional sliding seal mechanism with a magnetic coupling system. The magnetic field transfers force from the actuator to the valve stem without physical contact, eliminating mechanical friction and grinding movements while maintaining the sealing function through a different physical principle.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the actuator and the valve stem. This magnetic coupling allows force transmission without direct mechanical contact, thereby reducing friction losses while maintaining the necessary actuation and sealing functions.
2Reliability
If sliding seals (O-rings) are used, then sealing is achieved, but cycle time increases due to friction delays
Solution Approach 1:
By replacing the mechanical sliding seal with a magnetic coupling system, the patent eliminates friction-induced delays in valve actuation. The magnetic field provides instantaneous force transmission, significantly reducing cycle time while maintaining reliable sealing through the magnetic coupling mechanism.
3Ease of operation
If powerful actuators are used to overcome friction losses, then valve actuation is achieved, but device size increases
Solution Approach 1:
The patent replaces the need for powerful mechanical actuators with a magnetic coupling system that transmits force efficiently without friction losses. This allows for smaller, less complex actuators to achieve the same valve actuation performance, as the magnetic field directly couples the actuator force to the valve stem without energy loss to friction.
4Reliability
If frequent maintenance is performed on sliding seals, then valve functionality is maintained, but productivity decreases
Solution Approach 1:
By replacing the mechanical sliding seal requiring frequent maintenance with a magnetic coupling system, the patent eliminates the need for regular seal replacement and maintenance. The magnetic field system has no wearing parts, significantly reducing maintenance requirements and preventing system downtime while maintaining reliable valve functionality.
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 design reduces mechanical friction losses, lowers operating power, and extends service life by allowing faster switching times and simpler assembly, while avoiding manufacturing defects and the need for lubricants.
Implementation Method 1
an electromagnetic actuator (2) with an armature (11), a winding (12)
Implementation Method 2
a spring-elastic return element (10) interacting with this valve stem (17)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A pressure-balanced valve (1), preferably a 2/2-way valve for a gaseous working medium (compressed air), comprises a valve housing (3) with a valve chamber (6) and an electromagnetic actuator (2), wherein the valve (1) has at least one non-contact sealing element (20, 23, 25) for sealing the pressurized valve chamber (6). The actuator (2) comprises an armature (11), a winding (12), a coil former (13), a pole (14), a yoke (15), and an actuator housing (16), as well as a valve plunger (17) projecting into this actuator housing (16). This valve plunger (17) has an actuator-side valve pin (21) and an outlet-side valve plunger head (8), as well as a spring-loaded return element (10) cooperating with this valve plunger (17).The valve tappet head (8) is provided with a valve tappet head coating (9), wherein the spring-elastic return element (10) and the valve tappet head coating (9) are materially bonded together, i.e. forming an elastic molded part (18).