Pressure-Regulating Valve Element With Integrated Helical Springs
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Solution Overview
Problem
Existing pressure regulating valves require time-consuming assembly, testing, and maintenance due to factors like defects in Belleville springs and machining tolerances, necessitating multiple assembly and testing cycles to achieve desired regulated pressure.
Innovation Solution
A pressure regulating valve with a unitary valve element comprising integrally formed helical springs, specifically multi-start helical springs, and a poppet for flow control, manufactured using additive manufacturing, which simplifies assembly and calibration by allowing pre-fabrication and testing of the valve element before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Belleville spring sets are used in traditional pressure regulating valves, then the valve can provide pressure regulation function, but the assembly and testing process becomes time-consuming due to defects in springs and machining tolerances
Solution Approach 1:
The patent combines the spring set, regulating element, and valve body into a single integrally formed valve element using additive manufacturing. This merging eliminates the need for separate assembly of multiple components (Belleville springs, retainers, seals), directly resolving the time-consuming assembly and testing issues while maintaining reliable pressure regulation performance.
Solution Approach 2:
The valve element is pre-fabricated as a complete integrated unit with all spring components and sealing elements already in their final positions. This preliminary action of manufacturing the entire assembly in one piece eliminates the need for subsequent assembly steps and iterative testing, significantly reducing production time while ensuring consistent performance.
2Manufacturing precision
If multiple Belleville spring washers are used to achieve desired outlet pressure, then pressure regulation can be achieved, but the manufacturing process requires multiple assembly and disassembly cycles
Solution Approach 1:
The patent merges all spring components and regulating elements into a single integrally formed valve element. This eliminates the complexity of assembling multiple Belleville spring washers, retainers, and seals separately, while maintaining precise outlet pressure regulation through the unified design optimized via additive manufacturing.
Solution Approach 2:
The patent changes the manufacturing parameter from traditional subtractive or assembly-based methods to additive manufacturing. This enables the creation of complex spring geometries and integrated structures that achieve precise pressure regulation without requiring multiple assembly cycles, thereby improving both manufacturing precision and ease of manufacture.
3Ease of operation
If traditional spring sets are used in pressure regulating valves, then the valve can be assembled, but maintenance requires replacement of the entire Belleville spring set
Solution Approach 1:
The patent combines all spring components into a single integrated valve element that functions as one replaceable unit. This merging simplifies maintenance by eliminating the need to disassemble and replace multiple individual spring components, as the entire valve element can be replaced as a single unit, greatly improving ease of repair.
Solution Approach 2:
The patent segments the valve system into a modular valve element that can be easily removed and replaced as a complete unit. This segmentation allows for simplified maintenance where the entire spring assembly is replaced by simply removing and installing one component, rather than disassembling and replacing multiple individual parts.
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
Facilitates easier and faster assembly, reduces the need for lubricant, and lowers production costs by enabling accurate spring force determination and consistent performance, while reducing the complexity of assembly and maintenance processes.
Implementation Method 1
The spring typically comprises a plurality of Belleville spring washers... The at least one spring may comprise a helical spring... The helical spring may comprise a multi-start helical spring having multiple coils
Data Source
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AI summary
A pressure regulating valve (2) comprises a valve housing (6) comprising a pressure-regulating chamber (8) having an inlet (10) for high pressure fluid and an outlet (12) for pressure-regulated fluid, and a valve element (20) received in the pressure-regulating chamber (8) and movable axially therein for regulating the pressure of the fluid passing from the inlet (10) to the outlet (12). The valve element (20) comprises a regulating element (22) having a regulator head (24) slidably and sealingly received in the valve housing (6), the regulating element (22) extending into the regulating chamber (8), at least one spring (60), and an adjustment head (50) for adjusting an initial compression of the at least one spring (60) within the regulating chamber (8). The at least one spring (60) is integrally formed with and extends between the regulator head (24) and the adjustment head (50).