Continuous Molded Emitter for Drip Irrigation
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Solution Overview
Problem
Current drip irrigation systems face inefficiencies in water and fertilizer use, high labor and energy costs, and uneven water application, particularly on uneven terrain, due to limitations in emitter design and production speed.
Innovation Solution
A method for creating a continuous self-contained flow path unit with water inlets, flow regulating members, and outlets, which is extruded onto a substrate and then laminated to form a more defined and efficient emitter, allowing for higher production speeds and improved emitter definition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the flow path relies on its own structural integrity as it comes out of the rotary mold, then the flow path can be formed, but the extrusion speed is limited and the flow path will lose its definition at higher speeds
Solution Approach 1:
A support member is introduced as an intermediary element between the rotary mold and the flow path. The support member provides temporary structural assistance during the extrusion process, allowing the flow path to be formed at higher speeds without losing its definition. The support member is later removed, having served its purpose during formation.
2Productivity
If discrete emitters are installed internally or externally to the hose, then water flow can be regulated, but labor and energy costs increase
Solution Approach 1:
Multiple discrete emitter components are merged into a single continuous flow path structure. The flow path is formed as one continuous piece with multiple outlets, eliminating the need for separate emitter installations. This reduces assembly complexity and labor costs while maintaining water flow regulation functionality.
Solution Approach 2:
The flow path is created as a continuous structure rather than through discrete component assembly. The continuous formation process eliminates interruptions and manual installation steps, improving manufacturing efficiency and productivity while reducing labor requirements.
3Speed
If a continuous non-elastic strip is used to form emitters, then water distribution can be achieved, but the emitter definition becomes less effective at higher production speeds
Solution Approach 1:
The support member acts as a mediator that enables the continuous strip to maintain its shape during high-speed production. It provides the necessary structural framework that allows the non-elastic strip to be formed at higher speeds without compromising emitter definition.
4Productivity
If flood and sprinkler systems are used for irrigation, then water application can be achieved, but water and fertilizer use efficiency decreases
Solution Approach 1:
The irrigation system transitions from uniform water distribution (flood/sprinkler) to localized targeted delivery through the continuous flow path with specific outlets. Each outlet delivers water and fertilizer directly to the root zone of plants, improving resource use efficiency and reducing waste.
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
This approach enables increased production speed by up to 100% and enhances emitter definition, leading to more efficient water distribution and reduced costs through improved irrigation hose manufacturing processes.
Implementation Method 1
extruding a continuous flow path, the flow path having a bottom member and a plurality of features
Implementation Method 2
A continuous strip member is extruded onto the features, thereby enclosing the flow path and forming a self-contained flow path unit
Data Source
AI summary
A self-contained flow path unit (202), (302), (400), (500) includes a continuous flow path operatively connected to a continuous strip member to form a self-contained flow path unit. The self-contained flow path unit may be accumulated for later use in forming an irrigation hose.