Pressure Regulator Valve Element Step Design for Leakage Prevention
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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
The regulator incorporates a step on the outer peripheral portion of the pressure regulating valve element, allowing the piston portion to bias the valve element for closure, ensuring the valve remains closed even if the fixing portion is damaged, preventing unregulated high-pressure fluid flow and airtight leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the pressure regulating valve element and piston portion are fixed by press-fitting and welding, then the valve can be securely held in position, but the system becomes vulnerable to abnormal pressure increases and airtight leakage when the fixing portion is damaged
Solution Approach 1:
The patent applies beforehand cushioning by designing a backup mechanism (the large diameter portion) that automatically engages with the piston portion if the primary fixing method (press-fitting and welding) fails. This preventive design ensures that even when the fixing portion is damaged, the valve element remains secured and prevents abnormal pressure increases and airtight leakage.
Solution Approach 2:
The patent applies local quality by creating a specific structural feature (large diameter portion) at a particular location on the valve element. This localized structural modification provides enhanced securing capability at the critical interface between the valve element and piston portion, while leaving the rest of the valve structure unchanged.
2Reliability
If the valve element is designed with a large diameter portion for automatic engagement, then the valve remains closed even if fixing is damaged, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the valve element into distinct structural zones: the main body portion and the large diameter portion. This segmentation allows the large diameter portion to be manufactured as a separate feature using standard machining processes, reducing overall manufacturing complexity while achieving the reliability benefit of automatic engagement.
3Ease of operation
If separate pressure regulating valve element and piston portion are used, then assembly flexibility is improved, but the fixing portion becomes a potential failure point
Solution Approach 1:
The patent applies merging by integrating the large diameter portion directly into the valve element structure, creating a unified component that combines the sealing function with the mechanical engagement function. This reduces the number of separate parts and potential failure points while maintaining assembly flexibility.
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 configuration ensures safety by maintaining valve closure and preventing damage and leakage, even if the press-fitting and welding joint is compromised, while allowing for easy processing and reduced costs by eliminating the need for extensive welding.
Implementation Method 1
a pressure regulating spring 8 having a predetermined load disposed in an atmosphere chamber 61 provided in parallel coaxially with the pressure regulating chamber 4 around the piston portion 6
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
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A step (54) protruding from a fitting portion (53) to a piston portion (6) is provided at an upstream position displaced from a pressure regulating range at an outer peripheral portion of a pressure regulating valve element (5) .