Diaphragm pump housing having direct inlet channels to each chamber

Abstract

A diaphragm pump includes a pump housing with a pump head and a pump outlet, and features a splitter and three chambers. The splitter has a splitter inlet configured to receive fluid to be pumped, and having splitter channels configured to split the fluid received and provide splitter fluid from each splitter channel. Each chamber has a separate inlet cavity with a separate chamber inlet configured to receive the splitter fluid from a respective one of the splitter channels, and provide respective chamber fluid from each chamber to be pumped from the pump outlet.

Description

[0001] DIAPHRAGM PUMP HOUSING

[0002] HAVING DIRECT INLET CHANNELS TO EACH CHAMBER

[0003] CROSS-REFERENCE TO RELATED APPLICATION

[0004] This application claims benefit to provisional patent application serial no. 63 / 472,862, filed 14 June 2023, which is hereby incorporated by reference in its entirety.

[0005] BACKGROUND OF THE INVENTION

[0006] 1. Field of the Invention

[0007] The present invention relates to a diaphragm pump.

[0008] 2. Brief Description of Related Art

[0009] Known diaphragm pumps use a variety of chambers with valves to move fluids from the inlet of the pump to the outlet of the pump. These pumps come in a variety of configurations (e.g., 1 -chamber, 2-chamber, 3-chamber, 4-chamber, and 5-chamber are all common configurations) and can move fluids of various viscosities at various flows and pressures to be used in various applications. All known diaphragm pumps have a single inlet water connection and a single outlet water connection. A motor causes a cam within the pump to rotate and move components that cause suction to occur within the open volume inside the pump, which draws in fluid from the inlet and pushes fluid out the outlet of the pump. Diaphragm pumps that have multiple chambers that house valves typically have a single cavity at the inlet of the pump which is shared between the chambers. The inlet cavity acts as a manifold which distributes incoming fluid into each of the chambers within the pump. Figure 1 shows an example of a known 3- chamber diaphragm pump; while Figure 2 shows an underside of a pump head of the known 3-chamber diaphragm pump shown in Figure 1.

[0010] Shortcomings

[0011] Many of the known diaphragm pumps experience an air entrapment phenomenon which hinders pump performance. For example, if a diaphragm pump is pumping a liquid and air bubbles enter the pump, then they often tend to get trapped within the inlet cavity which causes one or more of the pump chambers to become short-circuited, thereby causing the pump to move liquid at a lower pressure and lower flow rate than the pump can normally produce when there are no air bubbles trapped within the pump. Since each typical pump chamber shares a single inlet cavity, when air bubbles get trapped in the cavity, water cannot flow into each chamber as it normally should but unintentionally bypasses one or more chambers. If a check valve is located inside of each pump chamber, when a diaphragm pump is operated under a certain system pressure, when air gets trapped in the pump, the back pressure from the outlet of the pump is too great for the liquid to open the check valve in the short-circuited chamber, which causes the air bubbles to remain trapped. Since air is compressible, when it gets trapped in a pump, it absorbs some of the force that is needed to push water in and out of the pump, so when the pump works to pull in and push out a liquid, the entrapped air buffers the pressure needed and compromises the ability to efficiently move the liquid. The larger the volume of the inlet cavity is, the larger the potential air bubble is that can be entrapped. The larger the air bubble entrapped is, the more pressure it can absorb and impede pump performance more greatly. Diaphragm pumps experience the air entrapment phenomenon to varying degrees, depending on system operating pressure, flow rate, or number of pump chambers. For example, when air enters diaphragm pumps that are pumping liquids, some diaphragm pumps experience air entrapment for as little as a few seconds, others experience air entrapment for a few minutes (sometimes the air bubbles escape over time partially or fully), while others remain in indefinite airlock as air bubbles cannot escape at all until system conditions change. Any delay in a pump’s ability to perform at its peak level, based on the pump specifications, can cause end users to suffer negative consequences. For example, if a diaphragm pump is used to supply water at a high pressure in a pressure washing system, if the pump experiences air entrapment, the system will not function properly, and the water pressure will not be high enough to wash off the target substances of the item being washed.

[0012] In view of the aforementioned shortcomings, there is a need in the industry for a better diaphragm pump that does not experience the air entrapment phenomenon which hinders known pump performance.

[0013] SUMMARY OF THE PRESENT INVENTION

[0014] In summary, the present invention provides a new diaphragm pump that overcome the aforementioned shortcomings of the known diaphragm pumps, and features one or more of the following:

[0015] (1 ) a manifold having direct channels from the inlet of the pump to each individual pump chamber, and / or (2) a minimized volume of cavities within the pump.

[0016] The manifold having direct channels allows liquid to be injected directly into each chamber, which makes short-circuiting of a chamber nearly impossible since the chambers no longer share an inlet cavity. The inlet of the pump has a splitter which divides the incoming liquid into direct channels to each separate chamber such that suction inside of the pump pulls liquid into the splitter, which naturally causes some liquid to flow into all chambers. Even when air bubbles get trapped in at least one of the chambers, the amount of liquid that is naturally forced into each chamber via the splitter increases over a short time and pushes the air out of each chamber. Moreover, minimizing the volumes of any cavities within the pump allows less space for air to accumulate and allows for less performance drop if air does somehow get trapped.

[0017] The present invention works best when both of these features are implemented together in one design but are not limited to that. For example, these features can be implemented separately and still contribute to improved pump performance.

[0018] Particular Embodiments

[0019] By way of example, and according to some embodiments, the present invention may include, or take the form of, a diaphragm pump having a pump housing with a pump head and a pump outlet, that features a new and unique combination of a splitter and chambers. The splitter has a splitter inlet configured to receive fluid to be pumped, and has splitter channels configured to split the fluid received and provide splitter fluid from each splitter channel. Each chamber has a separate inlet cavity with a separate chamber inlet configured to receive the splitter fluid from a respective one of the splitter channels, and provide respective chamber fluid from each chamber to be pumped from the pump outlet.

[0020] Other Features

[0021] The diaphragm pump may also include one or more of the following features:

[0022] The splitter may include splitter outlets, each splitter outlet configured to couple to a respective separate chamber inlet and provide the splitter fluid from each splitter channel to a respective separate inlet cavity.

[0023] Each chamber may include a separate chamber outlet configured to provide the respective chamber fluid from each chamber.

[0024] The pump head may include a center chamber configured to receive the respective chamber fluid from each chamber and provide center chamber fluid to the pump outlet.

[0025] The center chamber may include center chamber inlets, each center chamber inlet configured to receive the respective chamber fluid from each chamber.

[0026] The center chamber may include a center chamber outlet configured to provide the center chamber fluid to the pump outlet.

[0027] The center chamber may include a center chamber wall having the center chamber inlets and the center chamber outlet formed therein.

[0028] The chambers may be arranged around the center chamber.

[0029] Each chamber may include a respective chamber wall configured to form at least part of a respective separate chamber.

[0030] Each respective chamber wall may be formed at least partly as a cylindrical wall. Each separate inlet cavity may be isolated from all other separate inlet cavities.

[0031] The chambers may include at least two or more chambers, e.g. including three chambers, four chambers, five chambers, etc.

[0032] The splitter, or the chambers, or the splitter and the chambers may form part of the pump housing.

[0033] The splitter channels may be configured by molding, additive manufacturing, or subtractive manufacturing.

[0034] The splitter channels may be attached to the pump housing by attachments or fittings.

[0035] The cross sectional areas of the inlet channels and shapes of the inlet cavities may be dimensioned and vary in order to achieve an equal inlet volume for each chamber. For example, the cross sectional areas of the splitter channels are suitably dimensioned in order to achieve an equal inlet volume for each chamber; or the shapes of the inlet cavities are suitably dimensioned in order to achieve an equal inlet volume for each chamber; or the cross sectional areas of the splitter channels and the shapes of the inlet cavities are both suitably dimensioned in order to achieve an equal inlet volume for each chamber.

[0036] BRIEF DESCRIPTION OF THE DRAWING

[0037] The drawing, which is not necessarily drawn to scale, includes the following Figures:

[0038] Figure 1 shows a diagram having a section view of an example of a typical 3- chamber diaphragm pump that is known in the art. Figure 2 shows an underside of a pump head of the typical 3-chamber diaphragm pump shown in Figure 1.

[0039] Figure 3 is a diagram of a section view of an example of a pump with direct channels to each separate chamber, according to some embodiments of the present invention.

[0040] Figure 4 shows interior cavities of the pump head with the direct channels shown in Figure 3, according to some embodiments of the present invention.

[0041] Figure 5 shows an underside of the pump head with the direct channels to each separate chamber of the pump shown in Figures 3-4, according to some embodiments of the present invention.

[0042] DETAILED DESCRIPTION OF THE INVENTION

[0043] In summary, according to the present invention, and consistent with that shown in Figures 3-5, a diaphragm pump generally indicated as 10 may include separate inlet channels 24a, 24b, 24c (Figs. 3 and 4) so that liquid can flow from an inlet 22 of the pump 10 directly to each chamber 40a, 40c (Fig. 4) - the inlet cavities 42a, 42b, 42c (Fig. 5) to each chamber 40a, 40c are thus isolated from one another so that shortcircuiting cannot occur. (Note that Figure 4 does not show the third chamber which would be designated as element 40b and is understood to form part of the three chambers diaphragm pump as shown.) Consistent with that described above, short- circuiting occurs in multi-chamber diaphragm pumps like the diaphragm pump shown in Figures 1-2 when an air pocket absorbs the suction force from one or more chambers, which causes incoming liquid to flow through one of the other chambers, while bypassing at least one chamber that has air trapped within it.

[0044] By way of example, Figures 3 -5 show the cavities 42a, 42b, 42c within the three- chamber diaphragm pump 10 having the direct inlet channels 24a, 24b, 24c to each chamber 40a, 40c.

[0045] By way of further example, Figures 2 and 5 show the differences between a known 3-chamber diaphragm pump having one shared inlet cavity in the prior art and the new and unique 3-chamber diaphragm pump 10 according to the present invention having isolated inlet cavities 42a, 42b, 42c, e.g., where both are shown from the bottom of the pump housing 12. The new pump design having the direct channels 24a, 24b, 24c to each chamber 40a, 40c helps eliminate unnecessary volume within the diaphragm pump 10 so that air bubbles don’t have pockets to hide in and are always in the direct path of flow. The high velocity in the direct path of flow will help eliminate the air bubbles quickly.

[0046] By way of still further example, the individual inlet channels 24a, 24b, 24c can be arranged in a variety of different ways, as long as they guide incoming liquid directly into each pump chamber 40a, 40c. For example, the inlet channels 24a, 24b, 24c on the diaphragm pump 10 can be achieved in a variety of ways, including but not limited to, being built into the pump housing 12 via molding, additive manufacturing, or subtractive manufacturing, as well as by being attached to the diaphragm pump 10 externally via attachments or fittings that act as manifolds or internal inserts that create channels, tubes, or hoses that connect a liquid source (not shown) to each individual pump chamber 40a, 40c. The inlet port 22 and the outlet ports 16 of the pump housing 12 can be any type (threaded, quick-connect, clip-on, etc.).

[0047] Detailed Description of Figures 3-5

[0048] In particular, Figures 3-5 show the diaphragm pump 10 according to the present invention, e.g., that includes the pump housing 12 with the 14 and the pump outlet 16. The diaphragm pump 10 features a new and unique combination of a splitter or manifold 20 and three chambers like elements 40a, 40c (Fig. 4).

[0049] The splitter 20 has a splitter inlet 22 configured to receive inlet fluid Fi to be pumped, and has the splitter channels 24a, 24b, 24c configured to split the inlet fluid Fi received and provide splitter fluid SFa, SFb, SFc from each splitter channel 24a, 24b, 24c. Each chamber 40a, 40c has a separate inlet cavity 42a, 42b, 42c with a separate chamber inlet 44a, 44b, 44c configured to receive the splitter fluid SFa, SFb from a respective one of the splitter channels 24a, 24b, 24c, and provide respective chamber fluid CFa, CFb from each chamber 40a, 40c to be pumped from the pump outlet 16. Each chamber 40a, 40c may include separate chamber outlet like elements 46a and 46c (Fig. 4) configured to provide respective chamber fluid CFa, CFb from each chamber 40a, 40c to be pumped from the pump outlet 16.

[0050] The splitter 20 may include splitter outlets like elements 26a, 26c (Fig. 4), each splitter outlet 26a, 26c may be configured to couple to a respective separate chamber inlet 44a, 44c (Fig. 5) and provide the splitter fluid like SFa, SFc (Fig. 3) from each splitter channel like 24a, 24c to a respective separate inlet cavity like 42a, 42c. The pump head 14 may include a center chamber 50 (Figs. 4-5) configured to receive the respective chamber fluid from each chamber 40a, 40c and provide center chamber fluid Fee (Fig. 3) to the pump outlet 16, which provides outlet fluid Fo (Fig. 3). By way of example, the center chamber 50 may include center chamber inlets (not shown in Figure 5), a center chamber outlet 54 and a center chamber wall 56. Each center chamber inlet may be formed in the center chamber wall 56 and configured to receive the respective chamber fluid CF (Fig. 3) from each chamber 40a, 40c.

[0051] The center chamber outlet 54 may be configured to provide the center chamber fluid Fee to the pump outlet 16, e.g., as shown in Figure 3.

[0052] The chambers 40a, 40c may be arranged around the center chamber 50.

[0053] Each chamber 40a, 40c may include a respective chamber wall 48 configured to form at least part of a respective separate chamber 40a, 40c .

[0054] The diaphragm pump 10 may include a diaphragm and a motor and cam combination configured to rotate and cause the respective chamber fluid to flow from each chamber to the pump outlet. Such a diaphragm and such a motor and cam combination are not shown in Figures 3-5, but are known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof either now known or later developed in the future.

[0055] The Size and Shape of the Inlet Channels and Cavities

[0056] The scope of the invention is not intended to be limited to either the size or the shape of the splitter channels 24a, 24b, 24c or the inlet cavities 42a, 42b, 42c. For example, the cross sectional areas of the splitter channels and shapes of the inlet cavities may be dimensioned and vary in order to achieve an equal inlet volume for each chamber. In other words, embodiments are envisioned where the cross sectional areas of the splitter channels may be suitably dimensioned in order to achieve an equal inlet volume for each chamber; or where the shapes of the inlet cavities may be suitably dimensioned in order to achieve an equal inlet volume for each chamber; or where the cross sectional areas of the splitter channels and the shapes of the inlet cavities may both be suitably dimensioned in order to achieve an equal inlet volume for each chamber.

[0057] Possible Applications

[0058] This invention can be used for mechanically pumping any type of liquid. It is generally applicable to all multi-chamber diaphragm pumps and industries that use multi-chamber diaphragm pumps to move liquid. Such industries include, but are not limited to, beverage applications, sanitization, cleaning, marine applications, and recreational use. These pumps can be stand-alone pumps or built-in pumps within a system.

[0059] The Scope of the Invention

[0060] The embodiments shown and described in detail herein are provided by way of example only; and the scope of the invention is not intended to be limited to the particular configurations, dimensionalities, and / or design details of these parts or elements included herein. In other words, one skilled in the art would appreciate that design changes to these embodiments may be made and such that the resulting embodiments would be different than the embodiments disclosed herein, but would still be within the overall spirit of the present invention.

[0061] It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein.

[0062] Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.

Claims

WHAT WE CLAIM IS:1 . A diaphragm pump having a pump housing with a pump head and a pump outlet, comprising: a splitter having a splitter inlet configured to receive fluid to be pumped, and having splitter channels configured to split the fluid received and provide splitter fluid from each splitter channel; and chambers, each chamber having a separate inlet cavity with a separate chamber inlet configured to receive the splitter fluid from a respective one of the splitter channels, and provide respective chamber fluid from each chamber to be pumped from the pump outlet.

2. A diaphragm pump according to claim 1 , wherein the splitter comprises splitter outlets, each splitter outlet configured to couple to a respective separate chamber inlet and provide the splitter fluid from each splitter channel to a respective separate inlet cavity.

3. A diaphragm pump according to claim 1 , wherein each chamber includes a separate chamber outlet configured to provide the respective chamber fluid from each chamber.

4. A diaphragm pump according to claim 1 , wherein the pump head comprises a center chamber configured to receive the respective chamber fluid from each chamber and provide center chamber fluid to the pump outlet.

5. A diaphragm pump according to claim 4, wherein the center chamber includes center chamber inlets, each center chamber inlet configured to receive the respective chamber fluid from each chamber.

6. A diaphragm pump according to claim 4, wherein the center chamber includes a center chamber outlet configured to provide the center chamber fluid to the pump outlet.

7. A diaphragm pump according to claim 4, wherein the center chamber comprises a center chamber wall having the center chamber inlets and the center chamber outlet formed therein.

8. A diaphragm pump according to claim 4, wherein the chambers are arranged around the center chamber.

9. A diaphragm pump according to claim 1 , wherein each chamber comprises a respective chamber wall configured to form at least part of a respective separate chamber.

10. A diaphragm pump according to claim 9, wherein each respective chamber wall is formed at least partly as a cylindrical wall.11 . A diaphragm pump according to claim 1 , wherein each separate inlet cavity is isolated from all other separate inlet cavities.

12. A diaphragm pump according to claim 1 , wherein the chambers comprise at least two or more chambers.

13. A diaphragm pump according to claim 1 , wherein the splitter, or the chambers, or the splitter and the chambers form part of the pump housing.

14. A diaphragm pump according to claim 1 , wherein the splitter channels are configured by molding, additive manufacturing, or subtractive manufacturing.

15. A diaphragm pump according to claim 1 , wherein the splitter channels are attached to the pump housing by attachments or fittings.

16. A diaphragm pump according to claim 1 , wherein the cross sectional areas of the splitter channels are suitably dimensioned in order to achieve an equal inlet volume for each chamber.

17. A diaphragm pump according to claim 1 , wherein the shapes of the inlet cavities are suitably dimensioned in order to achieve an equal inlet volume for each chamber.

18. A diaphragm pump according to claim 1 , wherein the cross sectional areas of the splitter channels and the shapes of the inlet cavities are both suitably dimensioned in order to achieve an equal inlet volume for each chamber.

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