Damper Device Integral Welding Diaphragm Stress Reduction

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Solution Overview

Problem

Conventional damper devices for high-pressure pumps face issues with stress on welds due to diaphragm deformation and require additional manufacturing processes for resin component molding, which increases complexity and risk of separation between peripheral parts.

Innovation Solution

A damper device design featuring elastically deformable diaphragms with metal support components that are integrally welded, reducing stress on welds and eliminating the need for post-welding resin molding by providing structural support and maintaining the integrity of the damper chamber volume adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If resin component is used to cover peripheral parts of diaphragms, then diaphragms are protected from separation, but manufacturing complexity increases due to additional molding processes

Engineering Contradiction:

Improveprevention of diaphragm separationVSAvoidnumber of manufacturing processes

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the protective function from a separate resin component and integrates it directly into the metal diaphragm structure through integral formation. The peripheral protective portion is formed as an integrated part of the metal diaphragm body, eliminating the need for separate resin molding while maintaining the protective function against separation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the protective function with the structural function by forming the peripheral protective portion and the diaphragm body as a single integral metal structure. This combination eliminates the need for separate resin components and reduces manufacturing steps while ensuring reliable protection against diaphragm separation.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If resin component is molded after welding, then peripheral parts are protected, but stress concentration occurs on weld parts during diaphragm deformation

Engineering Contradiction:

Improveprotection of peripheral partsVSAvoidstress resistance of weld parts

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies preliminary action by forming the peripheral protective portion as an integral part of the metal diaphragm before welding operations. This pre-formed integral structure distributes deformation stresses more evenly and prevents stress concentration on weld parts during subsequent deformation operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes composite material properties by creating an integral metal structure with a peripheral protective portion that has different geometric characteristics from the diaphragm body. This integral metal composite structure provides both protection and stress distribution capabilities without requiring separate resin materials.

Inventive Principle:

Principle #40Composite materials

3Reliability

If multiple manufacturing processes are used for resin molding, then diaphragms are protected from separation, but production time increases

Engineering Contradiction:

Improveprevention of peripheral part separationVSAvoidmanufacturing cycle time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies segmentation by forming the peripheral protective portion as a distinct but integral part of the metal diaphragm structure. This segmented integral design allows for simplified manufacturing processes while maintaining the protective function, reducing production time compared to separate resin molding operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements self-service by designing the metal diaphragm with an integral peripheral protective portion that automatically provides protection against separation without requiring additional resin molding processes. The structure serves its own protective function, eliminating the need for separate protective components and reducing manufacturing steps.

Inventive Principle:

Principle #25Self-service

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 effectively reduces stress on welds, simplifies the manufacturing process, and enhances the reliability of the damper device by ensuring the peripheral parts remain supported and securely fixed within the pump housing, thereby improving the overall performance and durability.

Implementation Method 1

The first diaphragm has a first damper part which is elastically deformable... The second damper part is elastically deformable together with the first damper part to increase or decrease a volume of the damper chamber according to a pressure of fluid

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS8955550B2Damper device

Publication Date: 2015.02.17 DENSO CORP

AI summary

A damper device includes a first diaphragm having a first peripheral part, a second diaphragm having a second peripheral part, a first support portion disposed on the opposite side from the second peripheral part with respect to the first peripheral part, and a second support portion disposed on the opposite side from the first peripheral part with respect to the second peripheral part. The first peripheral part and the second peripheral part are supported between the first support portion and the second support portion. Radially outer sections of the first peripheral part, the second peripheral part, the first support portion, and the second support portion are integrally welded with each other.