Diaphragm Valve Quick-Lock Assembly for Fast Hygienic Replacement
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Solution Overview
Problem
Diaphragm valves experience significant wear and require frequent replacement, especially in aseptic applications, due to steam sterilization, and the current methods for replacing the diaphragm are time-consuming and inconvenient, often requiring complex structures for sealing.
Innovation Solution
A diaphragm valve design featuring a cap with internally threaded shafts and fixing elements, such as screws, and movable locking elements that allow quick detachment and reattachment of the valve body, enabling easy diaphragm replacement without obstructing access to fasteners, and maintaining simple internal and external sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve body and bonnet are assembled using multiple screws or bolts, then the connection is secure and reliable, but the diaphragm replacement becomes time-consuming and complex requiring operators to hold components in place and follow crisscross tightening patterns
Solution Approach 1:
The valve assembly is divided into modular components: a valve body, a separable bonnet, and a diaphragm assembly that can be independently replaced. The bonnet can be quickly detached from the valve body without requiring complete disassembly of all fasteners, enabling rapid diaphragm access and replacement while maintaining secure connection through the modular design.
Solution Approach 2:
The fastening system incorporates dynamic elements such as quick-release mechanisms or selectively loosenable fasteners that allow the bonnet to be rapidly detached for diaphragm replacement and then securely reattached. This dynamic fastening system transitions between locked and unlocked states, enabling both secure operation and rapid maintenance access.
2Strength
If traditional bolting systems are used to attach the bonnet to the valve body, then the structural integrity is maintained, but the reassembly process becomes inconvenient requiring operators to hold actuators and fasteners in place
Solution Approach 1:
An intermediary quick-connect mechanism or tool-assisted fastening system is introduced between the bonnet and valve body. This intermediary system provides locating features, alignment guides, or tool-retention mechanisms that prevent components from falling during assembly while maintaining strong structural connection when properly engaged.
3Reliability
If additional sealing parts such as Belleville rings and spring systems are added to ensure external sealing, then the sealing reliability is improved, but the valve structure becomes more complex
Solution Approach 1:
Multiple sealing functions are merged into integrated sealing elements or pre-assembled sealing units. Instead of separate Belleville rings, washers, and spring systems, the design combines these functions into unified sealing components that provide both external and internal sealing while reducing the number of individual parts and simplifying the overall structure.
Solution Approach 2:
The sealing system is designed with multi-functional elements that simultaneously provide external sealing, internal sealing, and diaphragm compression in a single integrated structure. This universal sealing approach eliminates the need for multiple separate sealing mechanisms, reducing complexity while maintaining comprehensive sealing reliability.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Valve comprising: - a valve body (2), - a sealing diaphragm (6), - a cap (10) attached to the sealing diaphragm, - a plurality of fixing elements (16) fixed to the cap (10), each having a head (40), and at least one locking element (15) held captive on the valve body, movable between an unlocked position where it allows the passage of the head of the corresponding fixing elements and a locked position where it engages under the head of the fixing elements to allow the fixing of the cap (10) to the valve body (2) by tightening the fixing element(s) (16).