Valve Diaphragm Rivet Joint for Turbocharger Stability
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Solution Overview
Problem
Existing valve designs for turbocharger overrun air recirculation, such as those with a pin connected to a diaphragm via a sleeve, suffer from weakened diaphragm stability and stress due to spring forces, particularly during lateral movements, which compromises long-term performance and rapid closing capabilities.
Innovation Solution
The diaphragm is riveted to the pin, providing a stable joint, and guided by elements like circumferential beads to center the spring, preventing damage and enhancing stability, with optional bead arrangements and material adaptability for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sleeve is pressed on or welded to the diaphragm to anchor the pin, then the pin can be connected to the diaphragm, but the diaphragm is weakened and long-term stability is compromised
Solution Approach 1:
The invention extracts the problematic sleeve component from the diaphragm assembly and replaces it with direct rivet attachment. The pin is riveted directly to the diaphragm base, eliminating the intermediate sleeve that caused weakening. This maintains manufacturing simplicity while removing the source of long-term stability issues.
Solution Approach 2:
The invention employs a composite construction where the diaphragm base is formed from plastic material that is integrally molded with the piston, and the rivet provides a metal-to-plastic mechanical fastening. This composite approach creates a stronger, more stable connection than sleeve attachment while maintaining the flexibility benefits of the plastic diaphragm.
2Device complexity
If the diaphragm is connected to the pin via a sleeve, then the valve structure is assembled, but the diaphragm is stressed by spring forces especially due to lateral relative movements
Solution Approach 1:
The sleeve is removed from the design, and the pin is riveted directly to the diaphragm base. This direct connection eliminates the lateral relative movements that occurred between the pin and diaphragm through the sleeve, thereby reducing stress on the diaphragm while maintaining acceptable structural complexity.
Solution Approach 2:
The invention incorporates a circumferential bead (guide element) on the diaphragm base that provides a curved guiding surface for the spring. This curved geometry centers the spring and prevents lateral movements, reducing stress on the diaphragm while maintaining simple device architecture.
3Device complexity
If the spring is not centered on the diaphragm, then the valve structure is simpler, but movement of the spring relative to the diaphragm causes damage
Solution Approach 1:
The circumferential bead on the diaphragm base creates a curved guiding surface that naturally centers the spring during compression and extension. This curved geometry passively guides the spring into proper alignment without requiring complex active centering mechanisms, maintaining simplicity while ensuring reliable operation.
Solution Approach 2:
The circumferential bead acts as an intermediary element between the spring and the diaphragm base. It provides a guiding function that centers the spring and prevents damaging lateral movements, while being integrally formed with the diaphragm base, thus adding minimal complexity to the overall structure.
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 ensures a stable and rapid valve closure with improved long-term performance by preventing diaphragm weakening and stress, allowing for secure and efficient operation of the valve.
Implementation Method 1
a solenoid (5) having a coil (6) and a metal pin (7) arranged in the housing (1)
Implementation Method 2
a spring (7a) that bears against the diaphragm
Data Source
AI summary
A valve comprising a housing, a solenoid in the housing, a pin that can be moved by the solenoid, and a cup-shaped piston connected to the pin. The piston has an injection-molded membrane as a base, and the pin is connected to the membrane. The valve further includes a spring that rests against the membrane. The membrane is riveted to the pin.