Split-Body Control Valve Structure for Low-Temperature Seal Integrity
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Solution Overview
Problem
Control valves used in cold-weather applications, such as hydrogen filling stations, face challenges with standard seals failing in low temperatures, leading to leakage and reduced operational reliability.
Innovation Solution
A split valve body design with coaxial bores and chambers, incorporating spring-energized seals and a piston mechanism to control fluid flow, allows for reliable operation in cold temperatures by maintaining seal integrity and reducing leakage points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard seals are used in cold-weather applications, then the control valve can be manufactured with conventional materials and processes, but the seals fail in low temperatures leading to leakage and reduced reliability
Solution Approach 1:
The valve body is divided into two separate portions (first body portion and second body portion) that are coupled together. This segmentation allows for better thermal management and reduces the impact of cold temperatures on seal performance by isolating critical sealing surfaces from the extreme environmental conditions.
Solution Approach 2:
The patent applies different surface finish qualities to different regions of the valve body. Specifically, the first bore and second bore have enhanced surface finishes (e.g., honed or polished surfaces) at the sealing interfaces, while other portions of the valve body can have standard machining finishes. This local quality improvement ensures reliable sealing in cold temperatures without requiring the entire valve body to be manufactured with high-precision processes.
2Reliability
If a split valve body design is implemented, then seal integrity is maintained in cold temperatures, but the device complexity increases
Solution Approach 1:
The valve body is segmented into two portions that can be manufactured separately using conventional processes and then assembled. This segmentation enables the use of standard manufacturing methods for each portion while maintaining overall reliability through proper design of the coupling interface and sealing surfaces.
Solution Approach 2:
The first body portion and second body portion are coupled together to form a complete valve assembly. This merging of two separately manufactured components creates a functional unit that maintains seal integrity in cold temperatures while allowing each portion to be produced using conventional, cost-effective manufacturing processes.
3Reliability
If enhanced surface finish quality is applied to bores, then sealing performance improves in cold temperatures, but manufacturing precision requirements and cost increase
Solution Approach 1:
The patent applies enhanced surface finishes (such as honing or polishing) only to specific critical regions of the bores where sealing occurs, rather than requiring the entire bore length to have high-precision surfaces. This localized approach maintains reliable sealing performance in cold temperatures while reducing overall manufacturing complexity and cost compared to uniformly high-precision machining of the entire valve 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
The split valve body design enhances the reliability and durability of control valves in cold temperatures, enabling efficient fluid control with reduced leakage and increased surface finish quality, suitable for high-pressure applications like hydrogen filling stations.
Implementation Method 1
The control valve also includes a spring. The spring is positioned within the chamber. In response to an input received at the input port, the piston compresses the spring and moves the valve plug between a closed position and an open position.
Implementation Method 2
In response to an input received at the input port, the piston compresses the spring and moves the valve plug between a closed position and an open position.
Data Source
AI summary
A control valve that includes a split valve body. The split valve body includes a first body portion, a second body portion, a flow path, an inlet port, and an outlet port. The flow path passes through the first body portion and the second body portion. The first body portion is coupled to the second body portion. The control valve also includes a valve seat. The valve seat is disposed between the first body portion and the second body portion. The control valve also includes a valve plug. The valve plug is movable relative to the valve seat to control fluid flow through the control valve.