Composite Diaphragm Bonding With Etched Hook Anchors
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Solution Overview
Problem
Existing composite diaphragms in diaphragm pumps face issues with insufficient bonding between thermoplastic elastomer bodies and metal inserts, leading to detachment under high surface forces and allowing compressed air ingress, which complicates manufacturing and reduces service life.
Innovation Solution
A composite layer with microscopic hook-shaped anchor elements is formed on the insert surface through etching, creating a strong bond with the elastomer body, eliminating the need for additional adhesives and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is added to bond the thermoplastic elastomer body to the insert, then the bonding strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the chemical bonding system (adhesive layer) with a mechanical bonding system (microscopic anchor elements created through surface etching). The anchor elements physically interlock with the elastomer material, providing strong bonding without requiring additional adhesive materials or complex multi-step manufacturing processes.
Solution Approach 2:
The insert surface is etched to create a porous structure with microscopic anchor elements. This porous surface allows the elastomer material to penetrate and interlock mechanically, creating a strong bond without requiring an adhesive layer. The porous structure is formed directly on the insert surface through controlled etching processes.
2Ease of manufacture
If the elastomer body is bonded to the insert without an adhesive layer, then the manufacturing process is simplified, but the bonding strength is insufficient under high surface forces
Solution Approach 1:
The patent applies local quality modification by creating anchor elements only in specific regions where bonding is critical. The etched composite layer with anchor elements is positioned at the bonding interface between the elastomer body and insert, providing enhanced local bonding strength without affecting the overall simplicity of the manufacturing process.
Solution Approach 2:
The patent changes the surface parameters of the insert by etching it to create a composite layer with microscopic anchor elements. This parameter change transforms the smooth surface into a structured surface with enhanced mechanical interlocking capability, significantly improving bonding strength while maintaining manufacturing simplicity.
3Force
If openings are provided in the insert for elastomer injection, then radial forces are compensated, but compressed air can still penetrate the gap between elastomer body and insert
Solution Approach 1:
The patent converts the potentially harmful effect of compressed air penetration into a beneficial sealing mechanism. The microscopic anchor elements created by surface etching act as sealing features that prevent compressed air from penetrating the bonding interface, while the injection openings remain open for elastomer material injection during manufacturing.
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 provides a stable, cost-effective bond that withstands dynamic loads, preventing elastomer detachment and air ingress, thereby extending the composite membrane's service life and reducing production complexity.
Implementation Method 1
The composite layer is designed with a plurality of hook-shaped anchor elements, wherein the elastomer body at least partially engages behind the anchor elements
Implementation Method 2
the composite layer is formed with a plurality of hook-shaped anchor elements, wherein the elastomer body at least partially engages behind the anchor elements
Data Source
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AI summary
The invention relates to a method for a composite diaphragm, particularly for diaphragm pumps, comprising an elastomer body (1) having a circumferential edge (2) with a clamping surface (3), a base (4), and a flexible diaphragm section (5) connecting the circumferential edge (2) to the base (4), wherein the base (4) forms a chamber (7) in which an insert (8) is arranged at least partially, and wherein the insert (8) is connected to the elastomer body (1) via a composite layer that forms the surface, at least partially. According to the invention, the composite layer (11) is formed with a plurality of hook-shaped anchor elements (12), wherein the elastomer body (1) at least partially engages behind the anchor elements (12), and wherein the composite layer (11) has a thickness of less than 100 µm.