3D-Printed Diaphragm Valve Structure for Leak-Free Assembly
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Solution Overview
Problem
Conventional diaphragm valve manufacturing involves multiple parts and assembly steps, leading to potential defects and leaks, and requires complex joining of housing components.
Innovation Solution
The diaphragm valve is manufactured as a single unitary piece using additive manufacturing, with elastomeric materials, and includes a return spring and actuator system to ensure proper operation and minimize assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional multi-part manufacturing method is used, then assembly flexibility is maintained, but manufacturing complexity and defect risk increase
Solution Approach 1:
The patent merges multiple separate components (housing parts, diaphragm, spring, actuator) into a single integrated unit manufactured via additive manufacturing. This consolidation eliminates the need for assembly operations while maintaining all functional requirements, directly resolving the contradiction between manufacturing simplicity and assembly flexibility.
2Reliability
If multiple housing parts are joined together, then component modularity is achieved, but leak risk and assembly defects increase
Solution Approach 1:
The housing is manufactured as a single monolithic piece using additive manufacturing, eliminating all joints, seams, and interfaces between housing parts. This integration completely removes the leak pathways that would exist at joining locations while reducing the total part count, directly addressing the contradiction between reliability and device complexity.
3Productivity
If traditional assembly methods are used, then manufacturing precision is maintained, but time consumption and productivity decrease
Solution Approach 1:
The additive manufacturing process performs all forming operations in a single continuous build process, pre-integrating all components during manufacturing rather than requiring post-manufacturing assembly. This preliminary integration eliminates assembly time and associated precision requirements, resolving the contradiction between productivity and manufacturing precision.
Data Source
AI summary
An oscillating diaphragm valve is provided. The valve is configured such that, when the diaphragm is in a closed position, pressure of a fluid supply opens the valve, and when the diaphragm is in an open position, the pressure of the fluid closes the valve. The valve internals are formed as a single, enclosed piece, with openings provided only for supply and consumption. The pilot-operated diaphragm-type valve uses a return spring for the diaphragm that applies a biasing force to an outside surface of the valve internals. Additionally, an actuator is provided to selectively arrest the diaphragm in an open or closed position by applying force to a different outside surface of the valve internals.