Self-Aligning Valve Poppet for Friction Reduction
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Solution Overview
Problem
Conventional gas flow pressure regulators face issues with misalignment and non-axial spring loads, leading to increased friction and valve seat wear, particularly in low flow systems like semiconductor manufacturing, resulting in performance degradation and leaks.
Innovation Solution
A self-aligning, axially constrained regulator valve poppet with a valve disc having a flexible portion and edge portion with a higher lateral spring force modulus than axial spring force modulus, utilizing spiral arms to self-align and axially constrain the valve disc within the valve seat, reducing friction and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring-loaded valve assemblies are used, then pressure regulation function is achieved, but misalignment and non-axial spring loads cause increased friction and valve seat wear
Solution Approach 1:
The valve disc is designed with a flexible portion that allows dynamic self-alignment during operation. The flexible portion can deflect to accommodate misalignment between the valve stem and valve seat, automatically adjusting to maintain proper alignment and reduce friction and wear on the valve seat.
Solution Approach 2:
The invention changes the stiffness parameter of the valve disc by creating regions of different flexibility. The flexible portion has controlled deflection characteristics that allow it to compensate for misalignment, while the edge portion maintains sufficient rigidity for proper seating. This parameter variation enables the valve to adapt to alignment variations without increasing overall structural complexity.
2Reliability
If rigid valve discs are used, then structural strength is maintained, but misalignment causes increased friction and performance degradation
Solution Approach 1:
The valve disc is designed with non-uniform local properties: the flexible portion has controlled flexibility to reduce friction through self-alignment, while the edge portion maintains higher rigidity for proper sealing. This local differentiation of mechanical properties allows the valve disc to simultaneously achieve friction reduction through flexibility and maintain structural strength where needed.
3Duration of action of stationary object
If misalignment compensation mechanisms are added, then valve seat wear is reduced, but device complexity increases
Solution Approach 1:
The flexible portion of the valve disc serves as a self-aligning mechanism that automatically compensates for misalignment during valve operation. This self-service feature eliminates the need for external alignment compensation mechanisms, extending valve assembly cycle life and reducing maintenance requirements without increasing device complexity.
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 significantly reduces friction and valve seat wear, ensuring precise alignment and extended cycle life without performance degradation, capable of running over two million cycles without noticeable change.
Implementation Method 1
The flexible portion of the valve disc has a lateral spring force modulus and an axial spring force modulus, wherein the lateral spring force modulus is greater than the axial spring force modulus so as to laterally align the valve disc and axially constrain the motion of the flexible portion.
Data Source
AI summary
A valve poppet (54) is provided for use in a regulator valve assembly (200) for regulating the pressure of a flowing gas through a gas flow pressure regulator (300). The valve poppet is includes a valve disc (54) having a flexible portion (60a) so as to permit upward and downward movement of a valve stem (52) in an axial direction. The valve disc may have an edge portion (60b) that provides a preloading force to self-align the valve disc within a valve seat (70), and axially constrain the motion of valve stem. The valve stem (52) may extend perpendicularly relative to the valve disc from a sealing portion (58). The movement of the valve stem is axially constrained and results in upward and downward movement of the flexible portion when the valve is opened and closed. The flexible and end portions of the valve disc may be formed of a plurality of spiral arms for self-aligning and axially constraining the valve disc.