Disc Spring Pressure Reducer for Compact Diaphragm Support
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Solution Overview
Problem
Existing pressure reducers require significant installation space due to the strength of conventional compression springs, compromising the overall design and efficiency.
Innovation Solution
A pressure reducer design incorporating a disc spring that supports the diaphragm and imparts forces on the piston rod, allowing for a compact and stable structure with reduced installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional compression spring is used to provide the necessary force for pressure reduction, then the strength and reliability are maintained, but the installation space and overall length of the pressure reducer increase significantly
Solution Approach 1:
The patent changes the geometric parameters and configuration of the spring from a conventional compression spring to a disc spring with specific dimensions (outer diameter, inner diameter, thickness, and curvature radius). This parameter change allows the spring to provide the same force while occupying less axial space, directly resolving the contradiction between strength and length.
Solution Approach 2:
The invention transitions from a one-dimensional compression spring (compressing along its length) to a two-dimensional disc spring (compressing radially with curvature). This dimensional change enables the spring to store and release energy in a compact form, reducing the axial length requirement while maintaining the necessary force output.
2Reliability
If a strong compression spring is used to ensure adequate force for pressure regulation, then the pressure reduction function is reliable, but the installation space required increases
Solution Approach 1:
The patent modifies the spring parameters by adopting a disc spring configuration with optimized curvature radius, thickness, and diameter ratios. These parameter changes enable the spring to achieve the same reliability in pressure regulation while reducing the installation area from what would be required by a conventional compression spring of equivalent strength.
Solution Approach 2:
The disc spring is pre-curved during manufacturing to store elastic energy in advance. This preliminary action allows the spring to immediately provide the necessary force when installed, ensuring reliable pressure regulation from the start without requiring a large installation space for gradual compression.
3Length of stationary object
If a compact spring design is implemented to reduce installation space, then the pressure reducer becomes more compact, but the stability of components may be compromised
Solution Approach 1:
The patent carefully selects and optimizes the disc spring parameters (outer diameter, inner diameter, thickness, and curvature radius) to ensure that the compact design maintains adequate stability. The curvature radius is specifically chosen to be within a range that provides both compactness and sufficient stability for supporting the diaphragm and guiding the piston rod.
Solution Approach 2:
The disc spring is designed to perform multiple functions simultaneously: providing force for pressure reduction, supporting the diaphragm, and guiding the piston rod motion. This multi-functionality ensures that the compact spring design does not compromise component stability, as the spring's geometry is optimized to fulfill all these roles effectively.
4Area of stationary object
If a disc spring is used instead of a compression spring to reduce installation space, then the compactness is improved, but the manufacturing complexity may increase
Solution Approach 1:
The patent specifies particular parameter ranges for the disc spring (curvature radius, thickness, diameter ratios) that balance compactness with manufacturability. These parameter changes are chosen to be within standard manufacturing capabilities, allowing the disc spring to be produced using conventional forming and cutting processes without excessive complexity.
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 disc spring provides strength comparable to conventional compression springs while requiring less space, enhancing stability and efficiency, and facilitating easy manufacturing.
Implementation Method 1
a disc spring (131) in the pressure reducer chamber (120). The disc spring (131) is coupled with the piston rod (121) and operatively supports a diaphragm (128)
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A pressure reducer (100) for reducing a fluid pressure includes a pressure reducer body (110) defining at least one pressure reducer chamber (120). The pressure reducer chamber (120) includes an inlet section (122) and an outlet section (124) fluidly coupled with the inlet section (122) such that the inlet section (122) and the outlet section (123) allow inlet and outlet of the fluid respectively. The pressure reducer chamber (120) further includes a disc spring (131) defining an inner diameter (D1) and an outer diameter (D2). A piston rod (121) is coupled with the disc spring (131) and a diaphragm (128) is operatively coupled with the piston rod (121). The pressure reducer (100) is characterized in that the disc spring (131) operatively supports the diaphragm (128).