Two-Part Rotary Valve Core for Complex Coolant Flow Sealing
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Solution Overview
Problem
Existing rotary valves for temperature control circuits in electromobility are costly and lack the capability for complex control of coolant flow, requiring intricate channel structures that are difficult to manufacture efficiently.
Innovation Solution
A rotary valve design with a two-part valve core, comprising an inner and outer part, where the outer part surrounds the inner part and forms a protective sleeve, allowing for complex channel structures to be created while ensuring a strong bond and effective sealing, using materials like plastic and elastomeric coatings, and connections via adhesives or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex channel structure is implemented in the valve core to enable sophisticated temperature control circuit functionality, then the control capability is improved, but the manufacturing cost and difficulty increase significantly
Solution Approach 1:
The valve core is divided into multiple separate components (first valve core component and second valve core component) that can be manufactured independently using standard processes, then assembled together. This segmentation allows each component to be produced cost-effectively while the combination provides the complex channel structure needed for sophisticated temperature control functionality.
Solution Approach 2:
The first valve core component is positioned within the second valve core component, creating a nested arrangement. This nesting enables complex three-dimensional channel structures to be achieved through the combination of simpler nested components, each manufacturable with standard processes, thereby providing high adaptability without proportionally increasing manufacturing difficulty.
2Reliability
If the valve core is made as a single integrated component to ensure structural integrity, then the reliability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The valve core is segmented into multiple components that are assembled together with precise positioning. The connection between components is designed to maintain fluid-tight sealing and structural stability, achieving reliable integrated functionality while allowing each segment to be manufactured separately with simpler, more cost-effective processes.
Solution Approach 2:
Multiple separately manufactured valve core components are combined through precise assembly and connection mechanisms (such as interference fits, adhesives, or mechanical fasteners) to create a functionally integrated valve core assembly that behaves as a single reliable unit while benefiting from the manufacturing advantages of segmented production.
3Adaptability or versatility
If multiple fluid openings are introduced into the chamber wall to enable complex coolant flow control, then the flow control capability is improved, but the sealing complexity and leak risk increase
Solution Approach 1:
The nested arrangement of valve core components within the valve housing creates multiple concentric sealing surfaces. Each component interface is designed with sealing elements (such as O-rings, sealing lips, or elastomeric materials) that prevent fluid leakage while allowing the complex multi-opening configuration needed for sophisticated flow control patterns.
Solution Approach 2:
Elastomeric sealing materials or flexible sealing lips are used at the interfaces between valve core components and the valve housing chamber wall. These flexible sealing elements conform to the mating surfaces and maintain reliable seals even with multiple fluid openings and complex geometric configurations, preventing internal and external leaks.
Data Source
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AI summary
Rotary valve (1) comprising a valve housing (2) with a valve chamber (3), wherein the valve chamber (3) has at least one chamber wall (4) in which at least two fluid openings (5) are provided, wherein the valve chamber (3) accommodates a valve core (7), wherein the valve core (7) is provided with a channel structure (8) which interacts with the fluid openings (5), wherein the valve core (7) is rotatably mounted in the valve chamber (3), and wherein the valve core (7) is formed in at least two parts.