Magnetic Actuator Armature Diaphragm Connection Noise Reduction
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Solution Overview
Problem
Diaphragm pumps used in exhaust gas aftertreatment systems for vehicles face challenges in durability and noise reduction, particularly when operating for extended periods and handling freezable reducing agents, requiring improved armature-diaphragm combinations to ensure quiet and efficient operation.
Innovation Solution
A magnetic actuator with an armature connected to an elastomer membrane via a thermoplastic injection molding, featuring a compression spring and a metallic stop for reduced noise, and a thermoplastic intermediate layer for enhanced material adhesion, ensuring a mechanically strong and durable connection between the armature and diaphragm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional armature-diaphragm connections are used, then the pump can operate, but the durability is insufficient and noise is high
Solution Approach 1:
The patent employs composite material construction by combining thermoplastic injection molding with elastomer membrane and metallic components. The armature consists of a thermoplastic base material reinforced with metallic inserts, creating a composite structure that provides both durability and noise reduction properties. This composite approach allows optimization of each material's characteristics to address both reliability and noise concerns simultaneously.
Solution Approach 2:
The patent introduces a thermoplastic intermediate layer between the metallic armature components and the elastomer membrane. This intermediate layer serves as a mediator that reduces noise transmission while maintaining the mechanical connection strength. The intermediate material absorbs vibrations and reduces direct contact noise between hard surfaces, thereby addressing the noise issue without compromising durability.
2Productivity
If the pump operates for extended periods to suck back reducing agent, then complete suction is achieved, but noise increases and durability decreases
Solution Approach 1:
The patent replaces traditional mechanical connection systems with a thermoplastic injection molded assembly that integrates the armature and membrane connection. This substitution reduces mechanical wear and noise generation during extended operation. The injection molded structure provides a more durable and quieter alternative to conventional mechanical fastening methods, enabling prolonged operation without excessive noise or durability loss.
3Strength
If strong connection between armature and diaphragm is achieved, then mechanical strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple components (armature, connection elements, and membrane attachment structures) into a single thermoplastic injection molded piece. This consolidation achieves strong mechanical connections through integrated design while simplifying manufacturing by reducing the number of separate parts and assembly steps. The merging principle allows the strong connection requirement to be met through monolithic construction rather than complex assembly of multiple components.
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 solution enhances the durability and noise reduction of the armature-diaphragm combination, ensuring efficient operation and complete suction of freezable reducing agents, even in non-resistant ice pressure conditions, while maintaining fluid-tight sealing and mechanical locking.
Implementation Method 1
A magnetic actuator (111) having an armature (118) which is connected to an elastomer membrane (117)
Implementation Method 2
a compression spring (18) and a metallic stop (122) for reduced noise
Data Source
Figure 1
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AI summary
The invention relates to a magnetic actuator (111) for a conveying unit (110), in particular a diaphragm pump for an operating medium/auxiliary medium in a vehicle, comprising a spring-loaded armature (118), which extends through a solenoid (14) and acts on a diaphragm (117), wherein the diaphragm can act on a working space (120) of the conveying unit and/or can cover or uncover a sealing seat (48) of a valve (130), wherein the diaphragm (117) is connected to the armature by means of an intermediate layer (119).