Sealant Injection Device with Dry-Zone Valve to Prevent Polymerization
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Solution Overview
Problem
Existing fluid material injection devices for air conditioning and refrigeration systems face issues with sealant leakage due to valve component failure and exposure to moisture, leading to polymerization and component jamming, resulting in high device failure rates and customer dissatisfaction.
Innovation Solution
A fluid material injection device with a movable contact member positioned downstream of the outlet valve, creating a 'dry zone' that prevents sealant contact and polymerization, and a Schrader valve system for controlled sealant release, ensuring the device remains operational and reducing O-ring swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluid outlet valve is used to contain sealant liquid, then the sealant can be dispensed when needed, but the valve components may fail to fully seat or leak during storage, causing sealant to contact moisture and polymerize, rendering the device useless
Solution Approach 1:
The device is divided into a wet zone containing the sealant and a dry zone containing the movable contact member and its seals. This segmentation prevents the movable components from contacting the sealant until the device is used, eliminating the harmful effects of polymerization and swelling while maintaining the valve's containment function.
Solution Approach 2:
A spaced arrangement with a gap acts as an intermediary barrier between the sealant in the wet zone and the movable contact member in the dry zone. This physical separation prevents direct contact and the associated harmful effects while allowing the device to function when needed.
2Reliability
If rubber O-rings are used to ensure liquid seal, then sealing is achieved, but the O-rings swell or shrink when exposed to sealant, causing dimensional changes that lead to leakage or component jamming
Solution Approach 1:
The O-rings and seals are extracted from the wet zone and placed in the dry zone, removing them from contact with the sealant. This eliminates the swelling and shrinking problems while preserving their sealing function when needed through the valve mechanism.
Solution Approach 2:
The movable contact member and its seals are pre-positioned in the dry zone in a state free from sealant exposure. This preliminary positioning prevents dimensional changes before use, ensuring stable components ready for operation when the device is activated.
3Ease of operation
If the outlet valve components are in direct contact with sealant, then the valve can control dispensing, but any leakage causes the sealant to polymerize and glue the components together, preventing movement
Solution Approach 1:
The valve system is segmented into a wet zone with the sealant and a dry zone with the movable contact member. This segmentation allows the valve to control dispensing through the outlet valve while keeping the movable components in the dry zone free from polymerization and gluing.
Solution Approach 2:
The spaced gap serves as an intermediary that prevents polymerized sealant from bridging the distance and gluing the movable contact member to the outlet valve. This maintains component mobility while preserving valve control function.
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 solution effectively prevents sealant leakage and polymerization, reducing device failure and customer dissatisfaction by maintaining the movable components in a dry state until use, ensuring reliable operation and minimizing dimensional changes in rubber components.
Implementation Method 1
a movable contact member located downstream of the outlet valve adjacent to but sufficiently spaced from the outlet valve to prevent any leaked sealant from contacting the moveable member and its associated seals
Implementation Method 2
the dispensing of a material such as a sealant liquid into a closed pressurized system utilizes the pressure difference between relatively high and low pressure zones of the closed system
Implementation Method 3
many rubber polymers such as silicone or buna that are normally used in the manufacture of O-rings to ensure a liquid or pneumatic seal, are highly prone to significant dimensional change caused by swelling or shrinkage when directly exposed to sealant
Data Source
AI summary
An injection device (10) injects a dispensable fluid material (32), for example, a liquid sealant, into refrigerant lines of an air conditioning or refrigeration pressurized system, by utilizing the pressure difference between high and low pressure zones of the pressurized system. The device comprises a tube (12) which contains the dispensable fluid material (32) and is closed by an outlet valve (26). A movable member (34) houses a spring-loaded check valve (38) and is disposed downstream of and spaced from the outlet valve (26). The movable member (34) is movable within a passageway (24e) formed in an outlet tube connector (24). Upon being connected to a service port (17) of a pressurized system by an installation nut (28), movable member (34) is forced into engagement with the outlet valve (26) to open it to dispense fluid material (32) into service port (17).