Diaphragm Pump Suction Valve Leak Structure for Stable Low Flow
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Solution Overview
Problem
Existing diaphragm pumps struggle to achieve a stable low flow rate without compromising performance stability and durability due to issues with torque shortage and valve wear.
Innovation Solution
A diaphragm pump with a suction valve featuring a leak structure that forms a channel between the valve body and the seat surface, allowing controlled fluid leakage and reducing wear, thereby stabilizing performance and extending durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the voltage applied to the motor is considerably lowered to suppress the discharge flow rate to a remarkably low flow rate, then the discharge flow rate is reduced, but the motor stops because of shortage of torque or the rotation becomes unstable making the pulsation of the pump motion large
Solution Approach 1:
The patent converts the harmful effect of motor instability at low speeds into a beneficial controlled leakage flow. By providing a leak structure in the valve body that intentionally allows fluid to leak from the pump chamber to the suction chamber, the system can maintain stable motor operation at higher speeds while achieving the desired low discharge flow rate through the controlled leakage path rather than through reduced motor speed.
2Productivity
If a leak structure is provided with a convex portion on the base that holds a diaphragm, then the discharge flow rate can be reduced, but if a foreign substance is put in the gap between the diaphragm and the convex portion on the base, the foreign substance cannot be removed basically making performance unstable
Solution Approach 1:
The patent extracts the leak structure from the base-diaphragm interface and relocates it to the valve body. The leak structure is formed as a specific groove or passage within the valve body structure itself, separating the leakage function from the diaphragm sealing function. This allows foreign substances to be removed from the diaphragm sealing area without affecting the leakage function, as the leak structure is located in the valve body where foreign substances can be flushed out through the suction and discharge passages.
3Productivity
If a leak structure is provided with a convex portion on the valve seat of a check valve, then the discharge flow rate can be reduced, but since the hardness of the valve seat is higher than the hardness of the check valve, the valve body of the check valve that repetitively comes into contact with the convex portion wears and dust is generated reducing durability performance
Solution Approach 1:
The patent introduces an intermediary soft sealing surface in the form of an O-ring or similar elastomeric seal that mediates between the hard valve body structure and the leakage function. The O-ring is installed in a groove on the valve seat and provides a compliant sealing surface that can deform to maintain sealing while accommodating the leak structure. This eliminates direct contact wear between hard surfaces while maintaining the controlled leakage path for flow rate reduction.
Data Source
AI summary
A diaphragm pump converts rotation of a motor into a reciprocating motion and drives a diaphragm. The diaphragm pump includes a partition configured to form a pump chamber together with a deformation portion of the diaphragm, a suction passage communicating with the pump chamber via a suction through hole extending through the partition, and a suction valve configured to open/close the suction passage. The valve body of the suction valve includes a leak structure configured to form a channel between the valve body and the seat surface of the partition.