Diaphragm Valve Mechanical Pressure Relief
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Solution Overview
Problem
Conventional metal flush valves in waste water systems are heavy, cumbersome, prone to corrosion, and costly, while plastic valves lack strength and fail to meet ASSE requirements for high fluid pressures, leading to inefficiencies and increased water usage due to wear and pressure fluctuations.
Innovation Solution
A plastic body flush valve with a vent system and mechanical relief assembly, featuring a solenoid with a piston to manage pressure differentials and a mechanical relief device that opens at predetermined pressures to prevent over-pressurization, ensuring reliable fluid flow and meeting ASSE standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal valves are used, then strength and ability to withstand high fluid pressures is improved, but weight and cost increase
Solution Approach 1:
The valve is divided into multiple components: a plastic valve body for the main structure, a diaphragm for sealing, and a metal reinforcement ring embedded in the diaphragm assembly. This segmentation allows each component to be optimized for its specific function - the plastic body reduces weight while the metal ring provides localized strength where pressure forces are applied.
Solution Approach 2:
The valve assembly uses composite construction by combining plastic material for the valve body with a metal reinforcement ring embedded in the diaphragm assembly. This composite approach allows the valve to achieve the strength of metal while maintaining the weight advantages of plastic, as the metal ring is strategically positioned only where structural support is needed.
2Strength
If metal valves are used, then strength and durability are improved, but corrosion and mineral deposit development occur
Solution Approach 1:
The valve employs a plastic body that is replaceable and designed to be cost-effective. While the plastic diaphragm may wear over time, the entire valve assembly can be replaced as a single unit at lower cost compared to traditional metal valves, and the plastic material itself is immune to corrosion and mineral deposit issues.
Solution Approach 2:
The invention changes the material parameter from metal to plastic for the valve body and diaphragm assembly. This material parameter change fundamentally alters the valve's interaction with water - plastic does not corrode like metal and does not promote mineral deposit formation, thereby eliminating these harmful effects while maintaining durability through the plastic material's inherent properties.
3Weight of moving object
If plastic valves are used, then weight and cost are reduced, but strength and ability to withstand high fluid pressures deteriorate
Solution Approach 1:
The valve is divided into multiple components: a plastic valve body for the main structure, a diaphragm for sealing, and a metal reinforcement ring embedded in the diaphragm assembly. This segmentation allows each component to be optimized for its specific function - the plastic body reduces weight while the metal ring provides localized strength where pressure forces are applied.
Solution Approach 2:
The valve assembly uses composite construction by combining plastic material for the valve body with a metal reinforcement ring embedded in the diaphragm assembly. This composite approach allows the valve to achieve the strength of metal while maintaining the weight advantages of plastic, as the metal ring is strategically positioned only where structural support is needed.
4Productivity
If conventional flush valves are used, then initial water flow is provided, but water usage increases over time due to wear and pressure fluctuations
Solution Approach 1:
The valve incorporates a diaphragm assembly with a metal reinforcement ring that maintains consistent valve opening characteristics. The rigid metal ring prevents deformation of the diaphragm under varying pressure conditions, ensuring that the valve opens to the same degree each time regardless of pressure fluctuations or wear, thereby providing feedback-stable water flow control.
Solution Approach 2:
Instead of trying to make the plastic diaphragm itself strong enough to resist pressure forces, the invention inverts the approach by embedding a metal reinforcement ring within the diaphragm assembly. This allows the flexible diaphragm to maintain its sealing and control functions while the metal ring bears the structural load, preventing wear-related deformation that would otherwise increase water usage over time.
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 provides a lightweight, cost-effective flush valve that maintains consistent water flow despite wear and pressure fluctuations, preventing leaks and damage from high pressures while adhering to ASSE requirements.
Implementation Method 1
The valve further includes a solenoid having a piston configured to move between a first position opening the vent outlet and a closed position closing the vent outlet
Implementation Method 2
The relief device, such a ball check valve, is configured to open and close the relief inlet based on a predetermined fluid pressure at the relief inlet, thereby venting fluid from the control chamber to the vent outlet
Implementation Method 3
The main valve element is adapted for movement to allow fluid flow between the fluid inlet and the fluid outlet based on a pressure differential across a portion of the main valve element
Data Source
AI summary
A flush valve for a waste water system includes a valve body and a vent system. The valve includes a fluid inlet, a fluid outlet and a main valve element extending therebetween and adapted for movement to allow fluid flow therethrough based on a pressure differential across a portion of the main valve element. The vent system includes a control chamber, in flow communication with the fluid inlet of the valve and a vent outlet in flow communication with the fluid outlet of the valve. The flush valve further includes a relief system including a relief chamber with a relief inlet in flow communication with the control chamber and a relief outlet in flow communication with the vent outlet. A mechanical relief device is configured to open and close the relief inlet based on a predetermined fluid pressure at the relief inlet, thereby venting fluid from the control chamber to the vent outlet. The flush valve may further include a solenoid having a piston configured to open to establish flow communication between the control chamber and the vent outlet to effect opening of the main valve element, and to close to prevent fluid communication between the control chamber and the vent outlet to close the main valve element.