Segmented Homogenizer Valve Axial Stacking
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Solution Overview
Problem
Existing homogenizer valves face challenges in efficiently regulating gap length and height at varying pressures and flows, leading to inefficiencies and increased costs, particularly in pasteurized milk processing, and suffer from uneven wear and limited adaptability.
Innovation Solution
A homogenizer valve design featuring multiple rotational-symmetric valve cones and seats with angled bevels and a threaded rod system allows for adjustable gap height and length, enabling uniform flow distribution and improved wear resistance, while being economical and suitable for retrofitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the homogenizer valve is made larger to increase flow quantity at lower pressure, then the flow capacity is improved, but the costs and device complexity increase significantly
Solution Approach 1:
The valve cone is divided into multiple segments (first, second, third valve cones) stacked axially, with each segment creating a separate homogenization gap. This segmentation allows the valve to handle higher flow quantities through multiple parallel gaps without increasing the overall valve diameter, thus maintaining compact size while improving productivity.
Solution Approach 2:
Instead of increasing flow capacity by enlarging the valve in the radial dimension, the invention extends the homogenization path in the axial dimension by stacking multiple valve cone segments. This dimensional transition allows multiple homogenization gaps to be arranged vertically, increasing total flow capacity without increasing valve diameter.
2Manufacturing precision
If the pressurized surface is increased to reduce gap height for better homogenization, then the homogenization quality is improved, but the forces and valve size increase
Solution Approach 1:
The total pressurized surface is segmented across multiple valve cones and seats, distributing the total force among several contact points. Each individual valve cone experiences reduced force compared to a single large valve, while the cumulative effect of multiple gaps maintains high homogenization quality through reduced effective gap height.
Solution Approach 2:
Multiple valve cones and seats are combined in series along the axial direction, creating multiple homogenization gaps that act together. The combined effect of these gaps achieves the desired reduced gap height for quality homogenization while distributing the mechanical forces across multiple components.
3Productivity
If parallel homogenization gaps are used to extend gap length and reduce gap height, then the homogenization efficiency is improved, but the gap height becomes fixed and wear becomes uneven
Solution Approach 1:
The valve cone segments are designed with movable connections allowing relative axial displacement between segments. This dynamic configuration enables the gap height to be adjusted by changing the axial position of individual valve cones, providing adaptability while maintaining the parallel gap structure for efficient homogenization.
Solution Approach 2:
The valve cone is segmented into movable sections that can be independently positioned, allowing the gap height to be varied. This segmentation enables adjustment of the homogenization parameters without changing the overall parallel gap structure, maintaining efficiency while adding versatility.
4Length of stationary object
If multiple concentric homogenization gaps are designed to extend gap length, then the gap length is increased, but the manufacturing complexity and wear control difficulty increase
Solution Approach 1:
Instead of creating complex concentric gaps within a single valve seat, the invention uses multiple separate valve cones stacked axially, each forming a simple radial gap with its corresponding seat. This segmentation simplifies manufacturing by using standard radial gap geometries repeated in series, avoiding the complexity of concentric machining while achieving extended effective gap length.
Solution Approach 2:
The invention transitions from radial concentric gaps to axial stacked gaps, arranging multiple homogenization gaps in the axial dimension rather than radially concentric. This dimensional change simplifies manufacturing as each gap can be formed by standard radial machining, while the axial stacking provides the extended effective gap length.
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 achieves efficient homogenization across varying pressures and flows, reduces wear, and allows for easy cleaning and adaptation, enhancing the homogenizer's capacity and performance in food handling applications.
Implementation Method 1
the fat globules of the fat emulsion are broken up as a result of the turbulence which occurs at great speeds
Implementation Method 2
through cavitation bubbles which implode in the liquid
Implementation Method 3
with the result that the liquid begins to boil
Data Source
Figure 1
Figure 1A
Figure 1B~2
AI summary
The invention relates to a homogenizer valve (1) which includes two or more pressurized, movable valve cones (5), two or more valve seats (6) and a valve housing (2) which surrounds the valve cones (5) and the valve seats (6). The valve cones (5) and the valve seats (6) are disposed so that throttles occur between them, which constitute homogenization gaps (7), which have a gap height h. The homogenization gaps (7) are disposed at an angle in relation to the horizontal plane. The homogenizer valve (1) is intended to be used in existing homogenizers and has been particularly produced to be able to obtain an efficient homogenization for liquids which are processed at a lower pressure and with a greater flow, such as, for example, pasteurized milk.