Pump diaphragm with improved seal geometry

Abstract

The present application provides a pump diaphragm having an improved seal geometry. A diaphragm for use with a pump assembly includes a flange, a cup wall extending from the flange and defining an interior volume having an opening, a plunger extending from the cup wall, the plunger configured to reciprocate by the pump assembly to move the cup wall to cyclically compress and expand the interior volume; and a seal extending from the flange such that the seal surrounds the opening, the seal including an outer sealing surface configured to engage a portion of the pump assembly. The outer sealing surface extends from the flange at an inclined angle such that the outer sealing surface converges from the flange toward a center of the opening.

Description

Technical Field

[0001] The present disclosure relates to diaphragms for pumps, and more particularly to seal configurations for compression chambers of diaphragms. Background Art

[0002] As will be described in further detail herein, pneumatic pump assemblies can utilize a movable diaphragm to generate an air flow. The diaphragm includes a seal to prevent air from leaking out of the pump assembly, and leakage would reduce the efficiency of the pump assembly. However, typical seal designs (i.e., beads) do not account for the thermal expansion that a pneumatic pump assembly may experience during operation. Typical seal designs also do not account for dimensional variations of components of the pump assembly. Thus, such seal designs may not effectively seal the pump assembly to prevent air from leaking out of the pump assembly during use. Summary of the Invention

[0003] The present disclosure provides a seal that, among other things, is capable of accommodating thermal expansion and dimensional variations of components of a pump assembly.

[0004] For example, in some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, the diaphragm including: a flange; a cup-shaped wall extending from the flange and defining an internal volume having an opening; a plunger extending from the cup-shaped wall, the plunger being configured to be reciprocated by the pump assembly to move the cup-shaped wall, thereby cyclically compressing and expanding the internal volume; and a seal extending from an upper surface of the flange such that the seal surrounds the opening, the seal including an outer seal surface configured to engage a portion of the pump assembly, wherein the outer seal surface extends from the flange at an inclined angle such that the outer seal surface is inclined from the upper surface of the flange toward the center of the opening.

[0005] In some aspects, the techniques described herein relate to a diaphragm, wherein the diaphragm is integrally formed as a single molded part.

[0006] In some aspects, the techniques described herein relate to a diaphragm, wherein the seal is an outer seal, and the diaphragm further includes an inner seal extending from the flange and spaced radially inwardly from the inner seal.

[0007] In some aspects, the techniques described herein relate to a diaphragm, further including a recess extending radially inwardly from the seal into the flange.

[0008] In some aspects, the techniques described herein relate to a diaphragm, wherein the inner seal has a first cross-sectional shape, and wherein the outer seal has a second cross-sectional shape different from the first cross-sectional shape.

[0009] In some aspects, the techniques described herein relate to a diaphragm, wherein the outer seal is configured to withstand a greater pressure than the inner seal.

[0010] In some aspects, the techniques described herein relate to a pump assembly including: a diaphragm including a wall, a plunger, an inner seal, and an outer seal, the wall defining an internal volume having an opening, the plunger being coupled to the wall, the inner seal extending around a perimeter of the opening, the outer seal surrounding the inner seal and being spaced apart from the inner seal; a plate coupled to the diaphragm opposite the plunger; and a drive mechanism configured to reciprocate the plunger to perform a cycle of compressing and expanding the internal volume, wherein the inner seal and the outer seal engage the plate to prevent air from entering or exiting the internal volume through an interface between the diaphragm and the plate.

[0011] In some aspects, the techniques described herein relate to a pump assembly further including a recess formed between the inner seal and the outer seal.

[0012] In some aspects, the techniques described herein relate to a pump assembly, wherein the inner seal tapers in a direction from the diaphragm toward the plate.

[0013] In some aspects, the techniques described herein relate to a pump assembly, wherein the outer seal tapers in a direction from the diaphragm toward the plate.

[0014] In some aspects, the techniques described herein relate to a pump assembly, wherein the inner seal has a first cross-sectional shape and wherein the outer seal has a second cross-sectional shape different from the first cross-sectional shape.

[0015] In some aspects, the techniques described herein relate to a pump assembly, wherein the diaphragm is a first diaphragm of a plurality of diaphragms.

[0016] In some aspects, the techniques described herein relate to a pump assembly, wherein the inner seal is more flexible than the outer seal.

[0017] In some aspects, the techniques described herein relate to a pump assembly, wherein the inner seal has an inner wall and an outer wall, wherein the inner wall is parallel to an axis of reciprocation of the plunger, and wherein the outer wall is inclined relative to the inner wall.

[0018] In some aspects, the techniques described herein relate to pumps, where the outer seal has an inner wall and an outer wall, where the inner wall is parallel to the axis of reciprocating movement of the plunger, and where the outer wall is inclined towards the inner wall.

[0019] In some aspects, the techniques described herein relate to a pump assembly, the pump assembly comprising: a diaphragm assembly including a plurality of diaphragms, each of the plurality of diaphragms including: a wall defining an internal volume having an opening; a plunger coupled to the wall; an inner seal extending around a perimeter of the opening; and an outer seal surrounding and spaced apart from the inner seal; a plate coupled to the diaphragm assembly; and a drive mechanism configured to reciprocate the plunger of each of the plurality of diaphragms to perform a cycle of compressing and expanding the internal volume, wherein the inner seal and the outer seal of each of the plurality of diaphragms engage the plate to prevent air from entering or exiting the internal volume through an interface between the diaphragm and the plate.

[0020] In some aspects, the techniques described herein relate to a pump assembly, where the diaphragm assembly is integrally molded as a single piece.

[0021] In some aspects, the techniques described herein relate to a pump assembly, where the drive mechanism is configured to reciprocate each of the plurality of diaphragms sequentially.

[0022] In some aspects, the techniques described herein relate to a pump assembly, where the inner seal has a first cross-sectional shape and where the outer seal has a second cross-sectional shape different from the first cross-sectional shape.

[0023] In some aspects, the techniques described herein relate to a pump assembly, where each of the inner seal and the outer seal includes an outwardly inclined surface.

[0024] In some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, the diaphragm comprising: a flange; a cup-shaped wall extending from the flange and defining an internal volume having an opening; a plunger extending from the cup-shaped wall, the plunger being configured to be reciprocated by the pump assembly to move the cup-shaped wall, thereby cyclically compressing and expanding the internal volume; a rim extending from an outer edge of the flange; a seal spaced from the rim and extending from an upper surface of the flange such that the seal surrounds the opening, the seal including an outer sealing surface configured to engage a portion of the pump assembly, wherein the outer sealing surface extends from the flange at an inclined angle such that the outer sealing surface slopes from the upper surface of the flange toward the center of the opening.

[0025] In some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, wherein the seal forms a generally trapezoidal shape in cross-section.

[0026] In some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, wherein the seal includes an inner surface spaced radially inward from the outer sealing surface, wherein the inner surface extends from the upper surface of the flange at an inclined angle such that the inner surface slopes from the upper surface of the flange toward the outer sealing surface.

[0027] In some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, wherein the outer sealing surface and the inner surface are angled such that the seal tapers in a direction away from the upper surface of the flange.

[0028] In some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, wherein the outer sealing surface includes a base and a sealing portion, wherein the base extends from the flange at a first inclined angle such that the base slopes from the upper surface of the flange toward the center of the opening, and the sealing portion extends from the base at a second inclined angle such that the sealing portion slopes from the base toward the center of the opening.

[0029] In some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, wherein the inner surface extends at a constant angle.

[0030] In some aspects, the techniques described herein relate to a diaphragm for use with a pump assembly, wherein the inner surface includes a plurality of portions.

[0031] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein a recess formed in the upper surface of the flange extends around the opening and forms a groove within the flange.

[0032] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein the seal is an outer seal and the diaphragm further includes an inner seal that extends around the perimeter of the opening and is radially inwardly offset from the outer seal by the recess, and wherein the recess is disposed between the inner seal and the outer seal.

[0033] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein the recess is generally semi-circular in cross-sectional shape and the recess abuts the inner surface of the seal.

[0034] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein the recess provides a release portion for radially inward deformation of the outer seal when the outer seal engages a plate that is oppositely coupled to the diaphragm from the plunger.

[0035] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein the flange does not include a recess disposed adjacent to the seal.

[0036] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein when the diaphragm is coupled to the plate, the outer surface is compressed against the head plate and bent inwardly to form a wider sealing surface against the head plate.

[0037] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein the inner seal can be more flexible than the outer seal.

[0038] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, further including a recess formed in the upper surface of the flange and disposed between the edge and the seal.

[0039] In some aspects, the techniques described herein relate to diaphragms for use with a pump assembly, wherein each of the outer seal and the inner seal is truncated.

[0040] In some aspects, the techniques described herein relate to a pump assembly that includes: a diaphragm having a wall, a plunger, and a seal, the wall defining an internal volume having an opening, the plunger being coupled to the wall, the seal extending around a perimeter of the opening and having a radially outer surface that is angled to converge toward a center of the opening; a plate coupled to the diaphragm opposite the plunger, wherein the plate is configured to engage the seal and bend the seal inwardly toward the center of the opening; and a drive mechanism configured to reciprocate the plunger to perform a cycle of compressing and expanding the internal volume.

[0041] Other aspects of the disclosure will become apparent by considering the detailed description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 is a perspective view of an embodiment of a pump assembly in accordance with the present disclosure.

[0043] Figure 2 is a schematic diagram of a pneumatic system in accordance with the present disclosure, the pneumatic system including Figure 1 the pump assembly of

[0044] Figure 3 is a cross-sectional view showing a pump assembly in accordance with the present disclosure.

[0045] Figure 4 is Figure 3 an exploded view of a portion of the pump assembly of

[0046] Figure 5 is Figure 3 an upper perspective view of a diaphragm assembly of the pump assembly of

[0047] Figure 6 is Figure 5 a partial cross-sectional view of the diaphragm of

[0048] Figure 7 is a partial cross-sectional view of a diaphragm in accordance with another embodiment of the present disclosure.

[0049] Figure 8 is a partial cross-sectional view of a diaphragm in accordance with yet another embodiment of the present disclosure.

[0050] Figure 9 is a partial cross-sectional view of a diaphragm in accordance with yet another embodiment of the present disclosure.

[0051] Figure 10 is a partial cross-sectional view of a diaphragm in accordance with yet another embodiment of the present disclosure.

[0052] Figure 11 is a partial cross-sectional view of a diaphragm in accordance with yet another embodiment of the present disclosure.

[0053] Before explaining any embodiments of the present disclosure in detail, it is to be understood that the present disclosure is not limited in its application to the details of the construction and arrangement of components set forth in the following description or shown in the following drawings. The present disclosure is capable of other embodiments and of being practiced or carried out in various ways. Further, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. Additionally, as used herein, the terms "upper", "lower" and other directional terms are not intended to require any particular direction, but are for descriptive purposes only. Detailed Description

[0054] Figure 1 A pump assembly 100 is shown that includes a first or upper housing 101 and a second or lower housing 102. In one embodiment, the pump assembly 100 is configured to provide air for use in an application such as in an automotive application. Such air can be provided from the pump assembly 100 through an upper housing outlet 103. The pump assembly 100 can include a pump that is configured to operate using an electrical connector 105 (i.e., to pump air through the upper housing outlet 103), and the electrical connector 105 can supply power to the pump assembly 100. The electrical connector 105 can be connected to a power source using a connector 104.

[0055] Figure 2 An embodiment of a pneumatic system 200 that includes the pump assembly 100 is shown. The pneumatic system 200 can be part of a vehicle. For example, in the embodiment shown, the pneumatic system 200 is part of a vehicle seating assembly. However, other applications of the pneumatic system 200 are contemplated, such as aerospace applications, office / desk chair applications, etc.

[0056] In the embodiment shown, the pneumatic system 200 includes a power source 201 that can be part of the electrical system of a vehicle. The connector 104 is configured to connect to the power source 201. In this way, the power source 201 can supply electrical power 202 (e.g., at 12 volts or 24 volts in some embodiments) through the electrical connector 105 via the connector 104 and supply it to the pump assembly 100.

[0057] When the pump assembly 100 is powered on, the pump assembly 100 can operate to pump air through the upper housing outlet 103. The air can flow from the upper housing outlet 103 through the pneumatic line 206. The pneumatic line 206 can include a valve 203 along or at either end of the pneumatic line 206. The valve 203 can be a single valve, and / or can be multiple valves, and, in either case, can be used to: (i) direct air from the pump assembly 100 along the pneumatic line 206; (ii) stop the airflow directed from the pump assembly 100 along the pneumatic line 206; (iii) regulate the pressure of the airflow through the pneumatic line 206; and / or (iv) regulate the flow rate of the airflow through the pneumatic line 206. Additionally or alternatively, the valve 203 can include a relief valve that can allow air to be discharged from the pneumatic line 206 to the atmosphere or to another connected pneumatic line.

[0058] The pneumatic line 206 can be connected to one or more bladders 205. The bladders 205 can be configured to expand or contract as air flows into or is removed from the bladders 205 from the pneumatic line 206. In one embodiment, the bladder 205 can be supported in a bladder support device 204. In some embodiments, the bladder support device 204 is a seat configured to be positioned within a vehicle. In one embodiment, the bladder 205 can be positioned within the bladder support device 204 to provide lumbar support when a user sits against the bladder support device 204. In such an embodiment, the user can provide a request to increase or decrease the lumbar support (e.g., the user can press a button), which can activate the pump assembly 100 to provide air from the pump assembly 100, provide air through the pneumatic line 206, and into the bladder 205 positioned within the bladder support device 204, thereby inflating the bladder 205 and providing the requested lumbar support.

[0059] Now referring Figures 3 to 4 , as previously described, the pump assembly 100 includes an upper housing 101 and a lower housing 102 connected to the upper housing 101. The electric motor 300 is at least partially disposed within the lower housing 102. The upper pump assembly 304 including the pneumatic pump 308 is at least partially disposed within the upper housing 101. Thus, the upper housing 101 and the lower housing 102 cooperate to enclose the electric motor 300 and the pneumatic pump 308.

[0060] A seal 312 ( Figure 3 ) is located between the upper housing 101 and the lower housing 102. The seal 312 is made of a flexible material such as rubber, silicone, or other resilient elastomeric materials. The seal 312 couples the upper housing 101 and the lower housing 102, and in some embodiments, the seal 312 can provide a vibration damping connection between the upper housing 101 and the lower housing 102.

[0061] Referring againFigure 3 , the upper pump assembly 304 includes an outlet plate 316 and an outlet plate fitting 320 that extends from the outlet plate 316 along the central axis A1 of the pump assembly 304. An outlet plate discharge passage 324 extends through the outlet plate 316 and the outlet plate fitting 320 and provides an outlet for air to leave the upper pump assembly 304.

[0062] The upper housing outlet 103 is located at one end of the upper housing 101, and in the illustrated embodiment, the upper housing outlet 103 includes an inner fitting 328 that extends from the inner side of the upper housing 101. A tube 342 interconnects the outlet plate fitting 320 and the inner fitting 328 such that air pumped by the pneumatic pump 308 can flow from the outlet plate discharge passage 324 through the tube 342 to the upper housing outlet 103.

[0063] Now referring to Figure 4 , the upper pump assembly 304 further includes a valve plate 346, a head plate 350, a diaphragm assembly 354, a rocking plate 358, an eccentric shaft 362, and a crank 366. The illustrated diaphragm assembly 354 includes a plurality of cup-shaped diaphragms 370 and associated plungers 374, each plunger 374 extending from the lower central portion of its associated diaphragm 370. Each plunger 374 includes a stem portion 378 that extends through the rocking plate 358; and a bead 382 that is formed on the stem portion 378 and has a diameter larger than the remainder of the stem portion 378. During assembly, the bead 382 of each plunger 374 is compressed and inserted through a corresponding hole 386 in the rocking plate 358. The hole 386 has a diameter smaller than the bead 382 to retain the stem portion 378 of the plunger 374 within the rocking plate 358. As described in more detail below, movement of the rocking plate 358 causes the plungers 374 to reciprocate, thereby compressing and expanding the diaphragms 370. In the illustrated embodiment, the diaphragm assembly 354 includes four diaphragms 370 and plungers 374; however, in other embodiments, the diaphragm assembly 354 may include one, two, three, five, or any other number of diaphragms 370 and plungers 374.

[0064] The rocking plate 358 is rotatably supported on the eccentric shaft 362 by a bearing 406. The eccentric shaft 362 is eccentrically mounted on the crank 366, which in turn is coupled for co-rotation with the output shaft 302 of the electric motor 300. Thus, the electric motor 300 rotates the crank 366, which in turn rotates the eccentric shaft 362. The eccentric shaft 362 is oriented and positioned such that rotation of the eccentric shaft 362 imparts a rocking motion to the rocking plate 358. More particularly, each corner of the rocking plate 358 moves up and down in a direction generally parallel to the central axis A1 in turn, which imparts a reciprocating (i.e., up and down) motion to the plungers 374 of the diaphragm assembly 354.

[0065] Continuing to refer to Figure 4, the header plate 350 includes an inlet opening 390 and an outlet opening 394, which are in fluid communication with the internal volume or compression chamber of each respective diaphragm 370. The valve plate 346 covers the header plate 350 and includes: a one-way inlet valve 398 in fluid communication with the inlet opening 390; and a one-way outlet valve 402 in fluid communication with the outlet opening 394. The inlet valve 398 and the outlet valve 402 are configured as reed valves in the illustrated embodiment and are integrally formed with the valve plate 346. In other embodiments, other types of one-way valves may be used.

[0066] In operation, as each plunger 374 moves upward, the internal volume of the associated cup-shaped diaphragm 370 is compressed. As the internal volume is compressed, air is discharged from the diaphragm 370 through the associated outlet opening 394 in the header plate 350 and the outlet valve 402 in the valve plate 346. The discharged air is directed into the outlet plate 316 and is ultimately discharged through the upper housing outlet 103. As each plunger 374 moves back downward, the internal volume of the associated diaphragm 370 expands, thereby drawing air into the internal volume of the diaphragm 370 through the associated inlet opening 390 and the inlet valve 398.

[0067] Reference Figures 5 to 6 , the illustrated diaphragm assembly 354 includes a flange 414 that generally surrounds the diaphragm 370 and has a flange upper surface 415 and a flange lower surface 417 ( Figure 6 ). In the illustrated embodiment, the flange upper surface 415 and the flange lower surface 417 are parallel and planar. Sides 419 extend from the outer ends of the flange 414. In the illustrated embodiment, the sides 419 include a plurality (e.g., four) of segments ( Figure 5 ); however, in other embodiments, the sides 419 may be a continuous edge surrounding the flange 414.

[0068] Continuing reference Figures 5 to 6 , each diaphragm 370 in the illustrated embodiment includes a diaphragm seal 418 that surrounds an opening 422 of the diaphragm 370. The seal 418 extends upward from the flange upper surface 415 in the direction toward the header plate 350 and is configured to engage and seal against the bottom side of the header plate 350. Each diaphragm opening 422 is aligned with a corresponding pair of inlet openings 390 and outlet openings 394 of the header plate 350 ( Figure 4 ). The illustrated diaphragm opening 422 is circular in a plane perpendicular to the reciprocating axis A2 of the plunger 374; however, the shape of the opening 422 may vary in other embodiments.

[0069] The diaphragm seal 418 extends around the perimeter of each opening 422 to enclose the opening 422 and seal each diaphragm 370 against the head plate 350. Thus, as the diaphragm 370 cyclically compresses and expands, air must flow through the outlet opening 394 and the inlet opening 390, respectively. That is, the seal 418 prevents air from entering or escaping at the interface between the diaphragm assembly 354 and the head plate 350. In some embodiments, as Figures 5 to 11 shown, the diaphragm assembly 354 (including the diaphragm 370, the flange 414, the edge 419, and the diaphragm seal 418) can be integrally formed as a single molded part and formed of a moldable and resilient material such as an elastomeric material.

[0070] Figure 6 A first embodiment of the diaphragm seal 418 that can be incorporated into the diaphragm assembly 354 is shown. Figure 6 The diaphragm seal 418 shown in includes a radially inner side 426 and a radially outer side 430. The radially outer side 430 forms a sealing surface that engages the head plate 350 to seal the diaphragm 370 to the head plate 350. The radially outer side 430 extends from the upper surface 415 of the flange 414 at an inclined angle. The orientation of the radially outer side 430 can also be defined by the inclined angle measured between the radially outer side 430 and a vertical axis A3 that extends perpendicular to the upper surface 415 of the flange 414 (i.e., parallel to the reciprocating axis A2 of the plunger 374). In the illustrated embodiment, the radially outer side 430 extends inwardly toward the inner volume of the diaphragm 370. Thus, the radially outer side 430 (i.e., the sealing surface) is inclined from the upper flange surface 415 toward the center of the opening 422 of the diaphragm 370.

[0071] In the illustrated embodiment, the radially outer side 430 includes a base portion 434 and a sealing portion 438. The base portion 434 extends from the upper surface 415 of the flange 414 at a first inclined angle, and the sealing portion 438 extends from the base portion 434 at a second inclined angle that is different from the first inclined angle. In the illustrated embodiment, the second inclined angle is greater than the first inclined angle. However, in other embodiments, the second inclined angle can be less than or equal to the first inclined angle.

[0072] Continuing to refer to Figure 6, the radially inner side 426 of the diaphragm seal 418 extends from the flange 414 to converge with the radially outer side 430. Thus, the diaphragm seal 418 is generally triangular or "fin-shaped" in cross-section. In some embodiments, the radially inner side 426 extends from the upper surface 415 of the flange 414 at an inclined angle. In other embodiments, the radially inner side 426 may extend perpendicularly from the flange 414. The illustrated diaphragm seal 418 is widest at the portion extending from the flange 414 and tapers toward the portion engaging the head plate 350. Unlike the radially outer side 430, the radially inner side 426 extends at a constant angle (i.e., does not have different base and sealing portions). However, in other embodiments, the radially inner side 426 may include multiple portions similar to the radially outer side 430.

[0073] In the illustrated embodiment, in the upper surface 415 of the flange 414, a recess 442 is formed adjacent to and radially inward of the radially inner side 426 of the diaphragm seal 418. The recess 442 extends around the opening 422 of the diaphragm 370 and forms a groove within the flange 414. In the illustrated embodiment, the recess 442 is generally semi-circular in cross-sectional shape and the recess 442 abuts the radially inner side 426 of the diaphragm seal 418. The recess 442 provides a release portion for the diaphragm seal 418 to deform radially inward as the diaphragm seal 418 engages the head plate 350.

[0074] During assembly, the head plate 350 compresses the outer side 430 of the seal 418 such that the diaphragm seal 418 deforms inwardly toward the interior volume of the diaphragm 370. Specifically, the sealing portion 438 of the radially outer side 430 engages the head plate 350 and the diaphragm seal 418 deforms radially inward.

[0075] The cooperating geometries of the inclined outer side 430 of the seal 418 and the recess 442 that allow the inward compression of the seal 418 provide an enhanced sealing area between the head plate 350 and the diaphragm 370. It has been found that this increased sealing contact performance between the head plate 350 and the diaphragm 370 improves the ability of the seal 418 to accommodate dimensional changes of the pump assembly 304, such as those caused by thermal expansion of the components of the pump assembly 304 and large differences in the specifications and shapes of the pump components (e.g., due to manufacturing tolerances), while maintaining the necessary seal.

[0076] Figure 7 A diaphragm seal 418a according to another embodiment of the present disclosure is shown, which can be incorporated into the diaphragm assembly 354. The diaphragm seal 418a is similar to the above-described diaphragm seal 418, where the same components have the same reference numerals with the addition of the letter "a" thereto, and the following explains the differences.

[0077] The radially outer side 430a of the diaphragm seal 418a is formed by a single surface that extends from the upper surface 415a of the flange 414a at an inclined angle inwardly toward the interior volume of the diaphragm 370a. The radially inner side 426a of the diaphragm seal 418a is also a single surface that extends from the flange 414a at an inclined angle. The radially inner side 426a and the radially outer side 430a are angled such that the diaphragm seal 418a tapers in a direction away from the flange 414a. The diaphragm seal 418a forms a generally trapezoidal shape in cross-section. In the illustrated embodiment, the radially inner side 426a and the radially outer side 430a extend at equal angles and are bisected by the vertical axis A3 of the diaphragm seal 418a. However, in other embodiments, the radially inner side 426a and the radially outer side 430a may extend at different angles (e.g., unequal magnitudes). Additionally, in the illustrated embodiment, the flange 414a does not include a recess disposed adjacent to the diaphragm seal 418a; however, in other embodiments, a recess similar to the recess 442 may be included.

[0078] Figure 8 A diaphragm seal 418b according to another embodiment of the present disclosure is shown, which can be incorporated into the diaphragm assembly 354. The diaphragm seal 418b is similar to the diaphragm seal 418 described above, where like components have like reference numerals with the addition of the letter "b" thereto, and the following explains the differences.

[0079] The diaphragm seal 418b is a radially outer seal, and the diaphragm 370b further includes a radially inner seal 446 that is offset from the radially outer seal 418b. In the illustrated embodiment, a recess 442b is provided between the radially inner seal 446 and the radially outer seal 418b, and the radially inner seal 446 and the radially outer seal 418b are asymmetric with respect to the recess 442b. The radially inner seal 446 includes an inner surface 450 and an outer surface 454. The inner surface 450 is oriented vertically or parallel to the reciprocation axis A2 of the plunger 374. The outer surface 454 is oriented at an inclined angle with respect to the reciprocation axis A2 ( Figure 5 ) and extends from the recess 442b in a direction toward the inner surface 450. In some embodiments, the outer surface 454 intersects the recess 442b at a point where the outer surface 454 is tangent to the recess 442b. Thus, the radially inner seal 446 is generally triangular in cross-sectional shape and tapers in a direction away from the flange 414b.

[0080] Figure 9 A diaphragm seal 418c according to another embodiment of the present disclosure is shown, which can be incorporated into the diaphragm assembly 354. The diaphragm seal 418c is similar to the diaphragm seal 418 described above, where like components have like reference numerals with the addition of the letter "c" thereto, and the following explains the differences.

[0081] The diaphragm seal 418c is similar to Figure 8 the diaphragm seal 418b. However, each of the radially outer seal 418c and the radially inner seal 446c is truncated to provide a wider peak compared to the outer seal 418b and the inner seal 446.

[0082] Figure 10 Shown is a diaphragm seal 418d according to another embodiment of the present disclosure, which can be incorporated into the diaphragm assembly 354. The diaphragm seal 418d is similar to the diaphragm seal 418 described above, where the same components have the same reference numerals and the letter "d" is appended thereto, and the following explains the differences.

[0083] The diaphragm seal 418d is similar to Figure 9 the diaphragm seal 418c. However, the radially outer side 430d of the outer seal 418d includes a single flat surface instead of a base surface and a sealing surface forming different inclined angles.

[0084] Figure 11 Shown is a diaphragm seal 418e according to another embodiment of the present disclosure, which can be incorporated into the diaphragm assembly 354. The diaphragm seal 418e is similar to the diaphragm seal 418 described above, where the same components have the same reference numerals and the letter "e" is appended thereto, and the following explains the differences.

[0085] The diaphragm seal 418e is similar to the diaphragm seal 418d; however, the diaphragm seal 418e includes a larger recess 442e disposed between the radially inner seal 446e and the radially outer seal 418e.

[0086] Each of the diaphragm seals 418 - 418e described and shown herein includes, among other things, an angled radially outer side 430 - 430e that converges towards the center of the opening 422 - 422e of the associated diaphragm 370. Thus, when the diaphragm assembly 354 is coupled to the head plate 350 ( Figure 4 ), the radially outer sides 430 - 430e are compressed against the head plate 350 and bent inward to form a wider sealing surface against the head plate 350, thereby improving the sealing performance (e.g., improving the airtightness of the seals 418 - 418e).

[0087] In some embodiments such as Figures 8 to 11In the embodiments shown, a radial inner seal 446c - 446e is provided to provide redundancy to further improve sealing performance. By providing two seals 418c - 418e, 446c - 446e, the total seal surface contact area with the head plate 350 is increased, thereby preventing air leakage. The seals 446c - 446e, 418c - 418e can also be optimized for performance at different pressure ranges. For example, in some embodiments, the geometry of the inner seals 446c - 446e can result in the inner seals 446c - 446e being more flexible than the outer seals 418c - 418e. The flexibility of the inner seals 446c - 446e can improve sealing performance at lower pressures, but may result in leakage at higher pressures. The reduced flexibility of the outer seals 418c - 418e can improve sealing performance at higher pressures to provide a backup seal in the event that air escapes past the inner seals 446c - e.

[0088] Although the present disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more of the independent aspects of the present disclosure as described.

[0089] The various features and aspects of the present disclosure are set forth in the claims.

Claims

1. A diaphragm for use with a pump assembly, the diaphragm comprising: flange; a cup-shaped wall extending from the flange and defining an interior volume having an opening; a plunger extending from the cup-shaped wall, the plunger being configured to be reciprocated by the pump assembly to move the cup-shaped wall to cyclically compress and expand the interior volume; as well as a seal extending from an upper surface of the flange such that the seal surrounds the opening, the seal including an outer sealing surface configured to engage a portion of the pump assembly, The outer sealing surface extends from the flange at an inclined angle, so that the outer sealing surface is inclined from the upper surface of the flange toward the center of the opening.

2. The diaphragm according to claim 1, wherein The diaphragm is integrally formed as a single molded component.

3. The diaphragm according to claim 1 or 2, wherein: The seal is an outer seal and the diaphragm further includes an inner seal extending from the flange and spaced radially inwardly from the inner seal.

4. The diaphragm of claim 1 further comprising a recess extending radially inwardly from the seal into the flange.

5. The diaphragm according to claim 3, wherein: The inner seal has a first cross-sectional shape, and wherein the outer seal has a second cross-sectional shape different than the first cross-sectional shape.

6. The diaphragm according to claim 5, wherein The outer seal is configured to withstand a greater pressure than the inner seal.

7. A pump assembly comprising: A diaphragm comprising a wall defining an interior volume having an opening; a plunger coupled to the wall; an inner seal extending around a periphery of the opening; as well as an outer seal surrounding the inner seal and spaced apart from the inner seal; a plate coupled to the diaphragm opposite the plunger; as well as a drive mechanism configured to reciprocate the plunger to perform a cycle of compressing and expanding the internal volume, Wherein the inner seal and the outer seal engage the plate to prevent air from entering or escaping the interior volume through an interface between the diaphragm and the plate.

8. The pump assembly of claim 7, further comprising a recess formed between the inner seal and the outer seal.

9. The pump assembly of claim 7, wherein: The inner seal tapers in a direction from the diaphragm toward the plate.

10. The pump assembly of claim 7, wherein: The outer seal tapers in a direction from the diaphragm toward the plate.

11. A pump assembly according to any one of claims 7 to 10, wherein: The inner seal has a first cross-sectional shape, and wherein the outer seal has a second cross-sectional shape different than the first cross-sectional shape.

12. A pump assembly according to any one of claims 7 to 11, wherein The diaphragm is a first diaphragm of a plurality of diaphragms.

13. A pump assembly according to any one of claims 7 to 12, wherein: The inner seal is more flexible than the outer seal.

14. A pump assembly according to any one of claims 7 to 13, wherein: The inner seal has an inner wall and an outer wall, wherein the inner wall is parallel to an axis of reciprocating movement of the plunger, and wherein the outer wall is inclined relative to the inner wall.

15. The pump assembly of claim 7, wherein: The outer seal has an inner wall and an outer wall, wherein the inner wall is parallel to an axis of reciprocating movement of the plunger, and wherein the outer wall is inclined toward the inner wall.

16. A pump assembly comprising: A diaphragm assembly, the diaphragm assembly comprising a plurality of diaphragms, each of the plurality of diaphragms comprising: a wall defining an interior volume having an opening; a plunger coupled to the wall; an inner seal extending around a periphery of the opening; and an outer seal surrounding the inner seal and spaced apart from the inner seal; a plate coupled to the diaphragm assembly; and a drive mechanism configured to reciprocate the plunger of each of the plurality of diaphragms to perform a cycle of compressing and expanding the internal volume, wherein the inner seal and the outer seal of each of the plurality of diaphragms engage the plate to prevent air from entering or escaping the interior volume through an interface between the diaphragm and the plate.

17. The pump assembly of claim 16, wherein: The diaphragm assembly is integrally molded as a single component.

18. A pump assembly according to claim 16 or 17, wherein The driving mechanism is configured to reciprocate each of the plurality of diaphragms in sequence.

19. A pump assembly according to any one of claims 16 to 18, wherein The inner seal has a first cross-sectional shape, and wherein the outer seal has a second cross-sectional shape different than the first cross-sectional shape.

20. A pump assembly according to any one of claims 16 to 19, wherein Each of the inner seal and the outer seal includes an obliquely oriented outer surface.

21. A diaphragm for use with a pump assembly, the diaphragm comprising: flange; a cup-shaped wall extending from the flange and defining an interior volume having an opening; a plunger extending from the cup-shaped wall, the plunger being configured to be reciprocated by the pump assembly to move the cup-shaped wall to cyclically compress and expand the interior volume; a rim extending from an outer edge of the flange; a seal spaced from the edge and extending from an upper surface of the flange such that the seal surrounds the opening, the seal including an outer sealing surface configured to engage a portion of the pump assembly, The outer sealing surface extends from the flange at an inclined angle, so that the outer sealing surface is inclined from the upper surface of the flange toward the center of the opening.

22. The diaphragm according to claim 21, wherein The seal forms a generally trapezoidal shape in cross section.

23. The diaphragm according to claim 21 or 22, wherein: The seal includes an inner surface spaced radially inwardly from the outer sealing surface, wherein the inner surface extends from an upper surface of the flange at an oblique angle such that the inner surface slopes from the upper surface of the flange toward the outer sealing surface.

24. The diaphragm according to claim 23, wherein The outer sealing surface and the inner surface are angled such that the seal tapers in a direction away from the upper surface of the flange.

25. The diaphragm according to claim 21, wherein The outer sealing surface includes a base and a sealing portion, wherein the base extends from the flange at a first inclination angle so that the base is inclined from the upper surface of the flange toward the center of the opening, and the sealing portion extends from the base at a second inclination angle so that the sealing portion is inclined from the base toward the center of the opening.

26. The diaphragm of claim 21 or 25, further comprising a recess formed in the upper surface of the flange, the recess radially inward from the seal toward the opening of the interior volume and adjacent to an inner side of the seal.

27. The diaphragm of claim 21 or 25, further comprising a recess formed in the upper surface of the flange and disposed between the rim and the seal.

28. The diaphragm according to claim 21 or 25, wherein The seal is an outer seal, and the diaphragm further includes an inner seal extending around a periphery of the opening and radially offset inwardly from the outer seal by a recess formed in the upper surface of the flange and disposed between the inner seal and the outer seal.

29. A pump assembly comprising: A diaphragm comprising a wall defining an interior volume having an opening; a plunger coupled to the wall; a seal extending about a periphery of the opening and having a radially outer surface angled to converge toward a center of the opening; a plate coupled to the diaphragm opposite the plunger, wherein the plate is configured to engage the seal and bend the seal inwardly toward the center of the opening; as well as A drive mechanism is configured to reciprocate the plunger to perform a cycle of compressing and expanding the internal volume.

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