Solenoid Valve Spring Pot and Sealing Integration
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Solution Overview
Problem
Existing electromagnetic valves for motor vehicle air spring systems face challenges in reliably installing sealing elements and optimizing support for valve springs, leading to high reject rates and limited design flexibility due to the difficulty in automating the fitting process and potential cavities in overmolding.
Innovation Solution
The introduction of a spring pot on the valve closing body, which has a tubular section that supports the valve spring and allows for adjustable positioning, reducing the risk of lateral displacement and enabling increased width for the undercut to accommodate the sealing element, thereby enhancing the valve's reliability and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a prefabricated sealing element is fitted onto the valve closing body, then the sealing element can be installed, but the fitting-on process can be automated only with difficulty
Solution Approach 1:
The sealing element is integrated directly into the valve closing body through overmolding, merging two previously separate components (sealing element and valve closing body) into a single integrated part. This eliminates the separate fitting-on process and enables automated manufacturing without manual assembly steps.
Solution Approach 2:
The sealing element is pre-formed as an integral part of the valve closing body during the overmolding process, rather than being attached later. This preliminary formation of the sealing element ensures proper positioning and eliminates subsequent installation steps, improving automation capability.
2Ease of manufacture
If the valve closing body is overmolded with plastic for molding a sealing element, then the sealing element is formed, but cavities may arise in the undercut which impair the functionality
Solution Approach 1:
The geometry of the undercut is modified by changing the angle parameters, specifically making the undercut angle greater than 90 degrees (e.g., 100-150 degrees). This parameter change prevents cavity formation during overmolding while maintaining the sealing element's gripping functionality, thus improving both manufacturability and reliability.
3Adaptability or versatility
If the support surface for the valve spring is relocated on the valve closing body, then design flexibility is achieved, but the valve spring would have to be lengthened
Solution Approach 1:
Instead of relocating the support surface along the axial direction (which would require a longer valve spring), the support surface is positioned laterally on the outer circumference of the valve closing body. This dimensional shift allows the valve spring to maintain its original length while achieving the desired positioning flexibility.
4Reliability
If the width of the undercut is increased to accommodate the sealing element, then the sealing element can be securely held, but the valve closing body geometry becomes more constrained
Solution Approach 1:
The undercut geometry is optimized by changing the angle parameter to greater than 90 degrees, which allows the undercut to provide secure gripping force for the sealing element while maintaining a compact overall geometry. This parameter optimization enables both reliable sealing element retention and greater design freedom for the valve closing body.
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
This solution allows for easier and more reliable installation of the sealing element, improved support for the valve spring, and increased design freedom, resulting in enhanced valve performance and reduced reject rates by ensuring secure and efficient operation.
Implementation Method 1
an elastic sealing element which is capable of bearing sealingly against the valve seat
Implementation Method 2
a restoring spring which acts on the assembly in a closing direction
Implementation Method 3
a valve spring which acts on the assembly in an opening direction
Implementation Method 4
a magnet armature which forms an assembly together with the valve closing body
Data Source
AI summary
An electromagnetic valve, in particular for a motor vehicle air spring system, has a valve closing body which, in its basic position, shuts off a valve outlet and, for this purpose, is pressed against a valve seat by a restoring spring. To assist the opening process, a valve spring is also provided. The valve spring is supported at one side on a valve seat body and at the other side on a spring pot, which is arranged on the valve closing body. Preferably, a tubular section of the spring pot bears, non-displaceably in a lateral direction, directly against the valve closing body. An elastic sealing element may either be arranged on the end side of the valve closing body, or held laterally by a section, which forms an enclosure, of the spring pot.