Adjustable Sleeve-Cone Valve Gap for Stable Emulsification Flow
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Solution Overview
Problem
Existing multi-gap valves used in emulsification and mixing processes are costly, complex, prone to failure, and difficult to clean, with gap height adjustments being challenging, especially under variable volume flows, leading to inconsistent product quality and potential cracking due to high actuating forces and pressure peaks.
Innovation Solution
A valve design featuring a sleeve and cone structure with an adjustable gap, where the sleeve's inner surface tapers towards the outlet and the cone has a central channel, allowing for precise gap control through axial adjustment using a force-controlled or path-controlled element, eliminating the need for multiple valve discs and spring elements, thus reducing complexity and increasing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple valve discs are stacked to form gaps for handling large volume flows, then the valve can process larger volume flows, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The valve body is segmented into an upper and lower part that can be separated, allowing the valve to be disassembled for cleaning while maintaining a simple single-piece valve disc design during operation. This segmentation enables CIP cleaning capability without requiring multiple stacked discs
Solution Approach 2:
The spring elements and centreing mechanisms are completely removed from the valve design. The valve discs are centreless and rely on hydraulic forces and geometric constraints for positioning, eliminating the need for separate centreing components and reducing overall device complexity
2Ease of operation
If spring elements are added to centre valve discs, then the valve discs are properly centred, but the radial installation space and overall valve size increase
Solution Approach 1:
Spring elements and mechanical centreing mechanisms are completely removed from the design. The valve achieves proper disc positioning through hydraulic forces during operation and geometric constraints in the closed position, eliminating the need for radial space dedicated to centreing mechanisms
Solution Approach 2:
Hydraulic forces are used to position and centre the valve discs during operation. The fluid pressure itself provides the centring action, replacing mechanical spring elements and reducing the need for dedicated centreing space
3Manufacturing precision
If the gap height is reduced to achieve desired emulsification properties, then the particle size is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The valve incorporates adjustable gap height through movable valve discs that can be positioned along the flow direction. This dynamic adjustment capability allows the gap to be optimized for different volume flows without requiring extremely precise fixed manufacturing tolerances, reducing grinding effort while maintaining emulsification quality
Solution Approach 2:
The gap height is made variable rather than fixed, allowing operational adjustment to compensate for manufacturing tolerances. This parameter change enables the system to achieve desired particle size distribution without requiring ultra-precise initial manufacturing
4Productivity
If the number of valve discs is increased to handle larger volume flows, then the productivity increases, but the reliability decreases due to more single parts
Solution Approach 1:
The valve body is segmented into separable upper and lower parts for cleaning purposes, but the valve discs themselves are kept as simple, few-number components without complex internal structures. This segmentation strategy maintains reliability by minimizing the number of valve disc components while still enabling cleaning capability
Solution Approach 2:
Centreing mechanisms and spring elements are removed from the valve disc design, leaving simple, robust discs with fewer potential failure points. The reduced component count per disc increases reliability while the overall valve handles large volume flows through the multi-disc arrangement
5Manufacturing precision
If excess actuating force is applied to adjust gap height, then the gap height is precisely controlled, but the bending stress on valve discs increases leading to potential breakage
Solution Approach 1:
The valve allows dynamic adjustment of gap height through controlled movement of valve discs. This dynamic adjustment enables precise gap control through gradual positioning rather than excessive force, reducing bending stress on the discs while achieving the required precision
Solution Approach 2:
The valve design incorporates preliminary geometric constraints and hydraulic pre-positioning that prepare the valve discs for optimal positioning before final gap adjustment. This preliminary action reduces the excess force needed for precise gap height control, protecting the discs from breakage
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 results in a more cost-effective, reliable, and easily cleanable valve with precise gap control, reducing the risk of cracking and improving product homogeneity by minimizing actuating forces and preventing pressure peaks, while enabling efficient operation under high pressures and varying flow conditions.
Implementation Method 1
The inner surface of the sleeve (3) facing the cone (4) tapers at least in sections towards the fluid outlet (6) and the outer surface of the cone (4) is conformed with the same inclination as the inner surface of the sleeve (3)
Implementation Method 2
When the expansion occurs, the desired crushing of the disperse phase is achieved due to turbulence and shear
Implementation Method 3
When the expansion occurs, the desired crushing of the disperse phase is achieved due to turbulence and shear
Data Source
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AI summary
A valve comprising: a housing (1); a valve body (2) having a fluid inlet (5) and a fluid outlet (6), the valve body (2) comprising a first valve element (3) and a second valve element (4) arranged in the housing (1); a gap (14) being formed between the valve elements (3, 4), the first valve element (3) being conformed as a sleeve (3) with an inner surface that tapers at least in sections towards the fluid outlet (6), the second valve element (4) being conformed as a cone (4) mounted in the sleeve (3), with the same inclination as the inner surface of the sleeve (3) so as to form the gap (14), an annular space (8) open to the fluid outlet (6) is formed between the sleeve (3) and the inner surface of the housing (1), the sleeve (3) has through holes (10) towards the annular space (8) and the cone (4) has through openings (9) towards the fluid inlet (5), the sleeve (3) and the cone (4) being axially adjustable relative to one another.