Flow Control Valve Sleeve With Backup Minimum-Flow Channels
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Solution Overview
Problem
Conventional flow control valves in hydraulic systems are complex and have a high number of parts, which increases weight, cost, and complexity, and they lack a reliable safety feature to ensure minimum fluid flow when components operate unintentionally, potentially leading to unsafe actuator movement.
Innovation Solution
A flow control valve with a multi-functional sleeve that integrates fluid flow channels and an orifice plug within the sleeve, reducing the number of parts and incorporating a safety feature to maintain a minimum fluid flow rate, even if unintended blockages occur, ensuring controlled actuator movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flow control valves use multiple separate components (housing, sleeve, seal carrier, end cap), then the valve achieves functional reliability, but the weight, cost, and complexity increase
Solution Approach 1:
The patent combines the housing, sleeve, seal carrier, and end cap into a single integrated body with molded-in features. The sleeve protrusions are formed directly on the body, fluid flow channels are molded into the body, and the seal carrier is integrated with the body structure, eliminating the need for separate housing, sleeve, and end cap components while maintaining sealing functionality
Solution Approach 2:
The single body structure performs multiple functions: it provides the housing structure, forms the sleeve with fluid flow channels, incorporates seal carrier functionality through integrated seal recesses, and includes end cap features through molded protrusions. This multi-functional design reduces part count while maintaining all necessary valve functions
2Ease of manufacture
If conventional flow control valves use multiple separate components, then assembly flexibility is maintained, but manufacturing cost and weight increase
Solution Approach 1:
The patent combines multiple valve components into a single injection-molded body, eliminating the need for separate housing, sleeve, and end cap parts. This integration reduces the total weight of the valve assembly and simplifies manufacturing by using a single molding process rather than multiple machining or assembly operations
Solution Approach 2:
The patent replaces traditional mechanical machining and assembly processes with injection molding technology. The complex internal fluid flow channels, sleeve protrusions, and seal recesses are all formed directly during the molding process, eliminating the need for separate machining operations and reducing manufacturing cost
3Reliability
If conventional flow control valves lack integrated safety features, then design simplicity is maintained, but reliability during unintended blockages is compromised
Solution Approach 1:
The patent incorporates backup fluid flow paths and relief features directly into the molded body structure before assembly. These safety features are pre-formed during manufacturing, ensuring that if unintended blockages occur during operation, alternative flow paths are already in place to prevent actuator damage without requiring additional components or complex assembly procedures
Solution Approach 2:
The safety features are integrated into the single body structure rather than being separate components. The relief channels, backup flow paths, and pressure relief features are molded directly into the body, combining safety functionality with the structural design and avoiding additional parts that would increase complexity
Data Source
AI summary
An example valve includes a housing, a sleeve disposed within the housing and having a first end and a second end opposite the first end, and the sleeve includes a plurality of sleeve protrusions at the first end and a plurality of fluid flow channels are formed between adjacent sleeve protrusions, a seal carrier disposed within the sleeve and having a carrier protrusion that extends from the second end of the sleeve and abuts against an interior surface of the housing, and an end cap mounted to the housing such that the plurality of sleeve protrusions abut against the end cap.