Integrated Diaphragm Valve Assembly for Clean Fluid Pathways
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Solution Overview
Problem
The assembly of diaphragm valves in industrial settings, such as semiconductor manufacturing and chemical factories, often results in contamination of fluid-contact areas due to the need to handle lubricants and metal components during assembly, which can lead to contamination of the fluid with lubricant and metal particles.
Innovation Solution
A diaphragm valve design where the pressurizing unit is assembled as a single integrated unit, allowing for connection to the valve mechanism without direct contact with internal components, eliminating the need for screwing between diaphragms and valve elements, and reducing friction and contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pressurizing unit is assembled as separate components requiring screwing between diaphragms and valve elements, then the device can be manufactured with standard assembly processes, but the fluid-contact areas become contaminated with lubricant and metal particles
Solution Approach 1:
The pressurizing unit is designed as a single integrated unit that combines the pressurizing mechanism, diaphragms, and valve elements into one pre-assembled component. This merging eliminates the need for separate assembly steps involving lubricant application and screwing operations, thereby preventing contamination of fluid-contact areas while maintaining manufacturing ease through modular installation of the complete unit.
Solution Approach 2:
The valve is divided into distinct functional modules: a contamination-free pressurizing unit that is pre-assembled in a controlled environment, and the valve body with fluid pathways. The pressurizing unit can be manufactured and assembled separately using standard processes, then installed as a complete module, separating the contamination risk from the fluid-contact areas.
2Ease of operation
If lubricant is applied to reduce friction during assembly of separate components, then the ease of operation during assembly is improved, but the reliability of fluid cleanliness is degraded
Solution Approach 1:
The pressurizing unit is pre-assembled as a complete, functional unit before installation into the valve body. All necessary assembly operations, including any lubricant application, are performed in advance in a controlled manufacturing environment. This preliminary action ensures that lubricant is confined to non-fluid-contact areas, maintaining fluid cleanliness reliability while still allowing ease of operation during the pre-assembly process.
Solution Approach 2:
The assembly operation that requires lubricant is extracted and performed separately on the pressurizing unit in a controlled environment, isolating it from the fluid-contact areas. The pressurizing unit is then installed as a complete unit, taking the lubricant application step out of the final valve assembly process and preventing contamination of the fluid pathways.
3Adaptability or versatility
If multiple separate components are used in the pressurizing unit, then the adaptability for different configurations is improved, but the device complexity increases
Solution Approach 1:
The pressurizing unit is designed as a universal, multi-functional integrated component that combines pressurization, sealing, and valve actuation functions within a single standardized module. This universal design maintains adaptability for different valve configurations and applications while reducing device complexity by eliminating the need for multiple separate components and their associated assembly variations.
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 design prevents contamination of fluid-contact areas by eliminating the need for direct handling of lubricants and metal components during assembly, ensuring cleaner fluid pathways and reducing the risk of particle contamination.
Implementation Method 1
a constant inward pressure is constantly applied to the first diaphragm 305 via a spring retainer 314 from a spring 313 disposed inside the first pressurizing chamber 308
Implementation Method 2
a constant inward pressure is constantly applied to the second diaphragm 306 using compressed air, for example, supplied to the second pressurizing chamber 309 from outside of the second pressurizing chamber 309
Data Source
AI summary
A diaphragm valve includes: a valve body having formed therein a first valve chamber, a second valve chamber and a communication passage communicating between the two valve chambers; a valve seat formed in the communication passage; a valve mechanism including a diaphragm supporting a valve element that comes in contact with and separates from the valve seat and a second diaphragm; a pressurizing unit being configured to pressurize the first diaphragm so as to press the valve element against the valve seat; and a bonnet for holding an outer peripheral part of the second diaphragm between the bonnet and the valve body. The pressurizing unit is configured as a single integrated unit holding therein a movable body that moves in conjunction with the valve element via a stem.