Diaphragm Pump Device for High-Pressure Viscous Media Delivery
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Solution Overview
Problem
Existing pump devices fail to reliably and cost-effectively deliver viscous media with high solid components at pressures above 200 bar and temperatures above 300°C due to seal destruction, high energy costs, and large drive assemblies required for high pressure operation.
Innovation Solution
A pump device comprising a first diaphragm pump head hydraulically coupled to a second diaphragm pump head with double-acting pistons and diaphragm control chambers, where refilling valves use a diaphragm control pressure greater than atmospheric pressure to compensate for pressure drops and reduce the force required for piston movement, allowing for efficient fluid delivery with smaller drive assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piston pumps are used to deliver viscous media with high solid components at high pressures and temperatures, then delivery capability is achieved, but seal destruction and piston scoring occur in relatively short time
Solution Approach 1:
The patent introduces a diaphragm as an intermediary element that separates the high-pressure product medium from the drive mechanism. The diaphragm transmits mechanical motion from the piston to the product medium without direct contact, eliminating seal destruction and piston scoring while maintaining high-pressure delivery capability.
Solution Approach 2:
The patent replaces the traditional mechanical piston-seal system with a diaphragm-based system. Instead of using mechanical seals that contact the piston, the invention uses a flexible diaphragm that can be actuated by pressure differences, substituting direct mechanical contact with a flexible barrier that maintains reliability under harsh conditions.
2Stress or pressure
If hydraulically driven diaphragms are used to achieve high pressures, then delivery pressure is improved, but design and material technology outlay increases significantly
Solution Approach 1:
The patent employs hydraulic principles by using a hydraulic fluid in the drive chamber to transmit force to the diaphragm. The hydraulic system allows for simple construction compared to other high-pressure mechanisms, achieving high pressures through fluid pressure transmission without complex mechanical linkages or specialized materials.
Solution Approach 2:
The patent changes the operating parameters of the hydraulic system, specifically using atmospheric or slightly above-atmospheric pressure in the drive chamber rather than requiring high-pressure hydraulic systems. This parameter change simplifies the design and reduces material requirements while still achieving the necessary diaphragm actuation for high-pressure delivery.
3Temperature
If remote valve head design is used to avoid high temperature strain, then temperature range is extended, but solid components may clog the pipeline between pulsator and valve head
Solution Approach 1:
The patent segments the pump into two separate diaphragm pump heads: a first pump head that handles the high-temperature product medium and a second pump head that operates at lower temperatures with the hydraulic fluid. This segmentation prevents solid components from clogging pipelines while maintaining the ability to handle high temperatures, as each segment performs its designated function without requiring long connecting pipelines.
4Stress or pressure
If very large pump drive assemblies are used to overcome high pressure, then delivery pressure is achieved, but investment costs and energy costs increase significantly
Solution Approach 1:
The patent employs a self-service mechanism where the pressure differential between the drive chamber and the product chamber automatically actuates the diaphragm. The system uses the existing pressure conditions to drive the pumping action, eliminating the need for large, energy-intensive drive assemblies. The diaphragm responds to pressure changes without requiring additional mechanical force from oversized motors or pistons.
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
Enables reliable and cost-effective fluid delivery at high pressures and temperatures by reducing the force needed for piston operation, minimizing investment and lifecycle costs, and preventing clogging issues with solid components.
Implementation Method 1
the diaphragm control chambers being impinged temporarily, during the refilling procedure, which is controlled by the diaphragm position, by a diaphragm control pressure, which is greater than atmospheric pressure and less than the system pressure
Implementation Method 2
a first diaphragm pump head having two or an integral multiple of two fluid delivery chambers and diaphragms associated therewith, which are hydraulically coupled to a second pump head for driving the first diaphragm pump head
Data Source
AI summary
The present invention relates to a pump device with a first diaphragm pump head having two or an integral multiple of two fluid delivery chambers and diaphragms associated therewith, which are hydraulically coupled to a second diaphragm pump head. The second diaphragm pump head has two additional fluid delivery chambers and additional membranes associated therewith, which are drivable by a double-acting piston via associated diaphragm control chambers, a refilling valve being connected in each case to the diaphragm control chambers and the diaphragm control chambers being temporarily impinged with a diaphragm control pressure, which is greater than atmospheric pressure, using the refilling valve. The piston may thus be activated using a relatively small force to achieve a delivery action.