Additively Manufactured Diaphragm Valve Internals for Leak Prevention
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Solution Overview
Problem
Conventional diaphragm valve manufacturing methods require multiple parts and assembly steps, leading to potential defects and leaks, and existing methods do not effectively prevent improper assembly.
Innovation Solution
The diaphragm valve is manufactured using additive manufacturing techniques, forming the valve internals as a single unitary piece with elastomeric materials, incorporating a return spring and actuator system externally to ensure proper operation and prevent leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multi-part manufacturing method is used, then ease of manufacture is improved, but reliability deteriorates due to assembly defects and leaks
Solution Approach 1:
The patent merges multiple separate components (housing parts, diaphragm, spring, and internal features) into a single monolithic structure manufactured via additive manufacturing. This eliminates assembly interfaces that cause leaks and defects, resolving the contradiction by prioritizing reliability through integration while the additive manufacturing process maintains ease of manufacture.
2Ease of manufacture
If multiple assembly steps are used, then ease of manufacture is improved, but manufacturing precision deteriorates due to improper assembly
Solution Approach 1:
The invention combines all valve components into one monolithic piece, eliminating multiple assembly steps. This resolves the contradiction by ensuring manufacturing precision through single-step additive manufacturing while the process itself remains accessible and easy to implement.
3Ease of manufacture
If two-part housing is used, then ease of manufacture is improved, but device complexity increases due to multiple components
Solution Approach 1:
The patent merges the two-part housing and all internal components into a single monolithic structure. This reduces device complexity by eliminating the need for multiple separate parts while the additive manufacturing process keeps production straightforward and accessible.
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.