Rotary Valve with Nested Rotors for Compact Air Control
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Solution Overview
Problem
Existing rotary valves for controlling air supply in inflatable devices require complex porting designs, leading to increased costs, manufacturing difficulties, and inaccuracies due to high torque requirements and potential air leaks, especially when complex sequences are needed.
Innovation Solution
A rotary valve system with a stator and two rotors, where the rotors have planar surfaces with ports and channels, and a drive mechanism using a belt or gear system to simplify the design, reduce parts, and enhance torque without a separate gearbox, allowing for precise control of air supply and exhaust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex porting sequences are implemented in existing rotary valves, then the desired sequence of inflation can be achieved, but the valve diameter increases, manufacturing cost increases, and manufacturing difficulty increases
Solution Approach 1:
The patent transitions from a single-plane porting system to a three-dimensional multi-layer rotor structure. Ports are distributed across multiple layers (first layer, second layer, third layer) with channels connecting them vertically and horizontally. This dimensional expansion allows complex inflation sequences to be achieved within a compact valve diameter by utilizing space in the vertical dimension rather than requiring increased radial dimension.
Solution Approach 2:
The patent implements nested rotors where a second rotor is positioned within the first rotor, and a third rotor is positioned within the second rotor. Each rotor contains ports and channels that work in coordination with the outer rotors. This nested configuration allows multiple porting sequences to be integrated in a compact arrangement, achieving complex inflation control without increasing overall valve diameter.
2Adaptability or versatility
If complex porting sequences are implemented in existing rotary valves, then the desired sequence of inflation can be achieved, but manufacturing cost and manufacturing difficulty increase
Solution Approach 1:
The patent divides the valve into multiple independent rotor components (first rotor, second rotor, third rotor) that can be manufactured separately using standard machining processes. Each rotor contains specific ports and channels that are easier to manufacture individually than a single complex integrated structure. The rotors are then assembled together with sealing elements, allowing complex porting sequences to be achieved through modular assembly rather than monolithic manufacturing.
3Manufacturing precision
If more complex porting is designed, then more precise sequence control is achieved, but separation between ports decreases leading to inaccuracies and air leaks
Solution Approach 1:
The patent utilizes vertical separation between port layers to increase the effective distance between adjacent ports. Ports in different layers (e.g., first layer ports vs. second layer ports) are separated by the thickness of intermediate structures and sealing elements, providing additional clearance beyond what would be available in a single-plane configuration. This multi-layer arrangement maintains port separation while achieving complex sequencing.
Solution Approach 2:
The patent employs flexible sealing elements including O-rings and elastomeric seals positioned between rotors and at port interfaces. These compliant sealing films conform to the mating surfaces of the nested rotors, creating reliable airtight seals even with tight tolerances. The flexible nature of these sealing elements compensates for minor manufacturing variations and maintains seal integrity throughout operation, preventing air leaks.
Data Source
AI summary
A rotary valve for controlling air supply in an inflatable device comprises a first rotor (11) and the second rotor (12) driven by motor (13) with a drive pulley (14) fixed directly onto its drive spindle (15). A toothed belt (16) driven by the drive pulley (14) engages with the toothed perimeter profile of the first rotor (11), to rotate rotors (11) and (12) relative to a stator (10). As the first and/or second rotor(s) are rotated, channels and ports on the airtight interfaces between the rotors (11, 12) and the stator (10) are connected and disconnected as required by the desired inflation sequence, including all the ports sealed in one position or all the ports exhausting to atmosphere in another position. The valve can be used in conjunction with any type of inflating device, where complex porting or air routing is required, the valve achieving this in a simpler manner.