Pressure Regulator Valve Step Locking Against Overpressure Leakage
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Solution Overview
Problem
Conventional regulators with separate pressure regulating valve elements and piston portions, fixed by press-fitting and welding, face issues with abnormal pressure increases and airtight leakage when the fixing portion is damaged, leading to unregulated high-pressure fluid flow and potential downstream component damage.
Innovation Solution
A regulator design where the pressure regulating valve element and piston portion are separately formed and fixed by press-fitting and welding, with a step protruding from the piston portion at an upstream position, allowing the piston portion to bias the pressure regulating valve element and close it when the fixation is released, preventing abnormal pressure increases and ensuring safety by locking the valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure regulating valve element and piston portion are fixed by press-fitting and welding, then the valve structure is stable and reliable, but when the fixing portion is damaged, abnormal pressure increases and airtight leakage occur
Solution Approach 1:
The patent applies beforehand cushioning by designing a backup closing mechanism using the step structure. When the primary fixing portion (press-fitting and welding) is damaged, the step structure automatically engages with the piston portion to close the valve, preventing abnormal pressure increase and leakage. This safety mechanism is built in advance to compensate for potential fixing portion failure.
2Manufacturing precision
If the pressure regulating valve element and piston portion are formed separately and fixed by press-fitting and welding, then the manufacturing precision can be improved, but the device complexity increases
Solution Approach 1:
The patent merges the valve element and piston portion into a single integrated component. This eliminates the need for separate press-fitting and welding operations, simplifying the assembly structure while maintaining manufacturing precision. The integrated design ensures proper positioning and alignment of the valve element relative to the piston portion without requiring additional fixing mechanisms.
3Ease of manufacture
If the pressure regulating valve element and piston portion are formed separately and fixed by press-fitting and welding, then ease of manufacture is improved, but safety is compromised when fixation is released
Solution Approach 1:
The patent incorporates a safety mechanism built into the valve body structure - a step feature that automatically closes the valve when the piston portion moves due to fixation failure. This beforehand cushioning ensures that even if the separate components become disconnected, the valve will close to prevent abnormal pressure increase, maintaining safety without compromising the ease of manufacture of separate components.
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 design effectively prevents high-pressure fluid from flowing unregulated, minimizing damage and airtight leakage, ensuring safety by maintaining the pressure regulating valve in a closed state even if the fixing portion is damaged, and allows for easy processing and secure locking of the pressure regulating valve element.
Implementation Method 1
the piston portion 6 is configured to be biased in the direction of the introduction port 21 of the passage 2 by a pressure regulating spring 8 having a predetermined load
Implementation Method 2
the load due to the pressure of the fluid acting on the piston portion 6 joined to the pressure regulating valve element 5
Data Source
AI summary
A regulator may include a main body portion, a pressure regulating chamber, a valve seat, and a piston pressure regulating valve. The piston pressure regulating valve may include a pressure regulating valve element having an end surface that is adjustable into close contact with at least a portion of the valve seat. The piston pressure regulating valve may also include a piston portion surrounding an outer periphery of the pressure regulating valve element. The piston portion may be slidable in an axial direction of a passage of the main body portion and may be biased via a pressure regulating spring disposed in an atmosphere chamber. The pressure regulating valve element may include a step protruding from a fitting portion to the piston portion at an upstream position disposed displaced from a pressure regulating range at an outer peripheral portion of the pressure regulating valve element.