Integrated Valve Manifold Structure for Low-Leak Modular Assembly
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Solution Overview
Problem
Existing manifold systems for fluid delivery are costly to produce due to increased assembly time and parts count, and they are prone to leaks and degradation from multiple mechanical fasteners.
Innovation Solution
A manifold system with integrated valves and modular construction, where the fluid inlet, nozzle outlet, plunger housing, collar, and mounting structure are integrally constructed, reducing the number of discrete components and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If valves are attached to the manifold via mechanical fasteners in piecewise fashion, then the manifold can be assembled with individual valves, but the assembly time and parts count increase resulting in higher production costs
Solution Approach 1:
The valve body is integrally formed with the manifold body as a single piece, eliminating the need for separate valve components and mechanical fasteners. This merging of previously separate parts (manifold and valve) into one integrated component directly reduces parts count and assembly complexity while lowering production costs.
Solution Approach 2:
The integrated manifold-valve structure serves multiple functions simultaneously: it distributes fluid through the manifold passages while incorporating valve sealing surfaces and plunger mechanisms within the same body, eliminating the need for separate valve assemblies and reducing the overall parts count.
2Reliability
If multiple mechanical fasteners are used to attach valves to the manifold, then the valves can be securely mounted, but the likelihood of leaks and degradation increases
Solution Approach 1:
By integrating the valve body with the manifold body into a single piece, the invention eliminates all mechanical fasteners and sealing interfaces between separate components. This removes the sources of potential leaks and fastener degradation while maintaining secure valve mounting through the integral structure.
Solution Approach 2:
The integrated design eliminates the need for replaceable fasteners and seals that can degrade over time. The single-piece construction removes these vulnerable components entirely, creating a more reliable system without requiring periodic maintenance of fastening elements.
3Adaptability or versatility
If modular valve banks are constructed to allow expansion from one valve to many, then the manifold can be scaled without remachining, but the assembly time and parts count increase
Solution Approach 1:
The manifold is designed with multiple identical integrated valve bodies that can be arranged in modular configurations. Each valve-in-manifold unit can be independently manufactured and then assembled with other units through simple coupling mechanisms, allowing scalable expansion without increasing overall assembly complexity.
Solution Approach 2:
The integrated manifold-valve design creates universal building blocks that can be replicated and combined in various configurations. The same integral structure serves as both a single-valve unit and a scalable module, maintaining consistent assembly procedures regardless of the number of valves in the bank.
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 integrated manifold system reduces production costs, minimizes the likelihood of leaks, and enhances durability by reducing the number of components and mechanical fasteners, while maintaining accurate fluid delivery.
Implementation Method 1
The integrated valve may further include a plunger spring and a plunger cap. The plunger spring may be arranged between the plunger cap and the plunger arm and urge the plunger arm to a position where the fluid inlet of the plunger seat is closed.
Implementation Method 2
The integrated valve may be configured to receive pressurized air to cause the plunger arm to open a fluid inlet defined by the plunger seat
Data Source
AI summary
A manifold for use with a fluid delivery system includes a fluid inlet defining a portion of a common channel, a fluid nozzle outlet, a plunger housing of an integrated valve, a collar of a coupling mechanism, and a mounting structure. The fluid inlet, fluid nozzle outlet, plunger housing, collar and mounting structure of the manifold are integrally-constructed. A manifold assembly for use with a fluid delivery system includes at least a first and a second manifold. Each manifold includes a fluid inlet defining a portion of a common channel, a fluid nozzle outlet, a plunger housing of an integrated valve, and a collar of a coupling mechanism. The fluid inlet, fluid nozzle outlet, plunger housing, and collar are integrally-constructed, and the fluid inlet of the first manifold is received by a portion of a common channel of the second manifold.