Double-Membrane Valve Structure for Membrane Failure Detection
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Solution Overview
Problem
Existing ice cream machines face issues with valve integrity due to membrane breakage under pressure, leading to product spillage and machine downtime, necessitating robust and reliable valves to prevent air from reaching flexible containers.
Innovation Solution
A valve design featuring dual deformable membranes and a non-sealed mechanical coupling between shells to ensure correct operation, allowing immediate detection of membrane failure and preventing air from reaching containers, thus avoiding spillage and downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single deformable membrane is used in the valve, then the valve structure is simple, but the membrane may break under pressure causing air to reach the flexible container
Solution Approach 1:
The valve is divided into two separate chambers (first control chamber and second control chamber) each with its own deformable membrane (first membrane and second membrane). The membranes are arranged in series between the pneumatic actuator and the flexible container, so that if one membrane breaks, the other still provides protection. This segmentation increases reliability while maintaining reasonable structural complexity.
Solution Approach 2:
The dual-membrane design acts as a protective barrier against potential membrane failure. By having two membranes in series, the system provides beforehand protection against the harmful effect of air reaching the flexible container due to membrane breakage. This redundancy ensures that even if one membrane fails, the other continues to prevent air leakage.
2Power
If the valve is sealed tightly, then air pressure is effectively transmitted, but membrane failure cannot be detected promptly
Solution Approach 1:
The harmful effect of complete sealing is extracted by introducing a controlled leakage path through the non-sealed mechanical coupling between the first and second shells. This coupling allows atmospheric pressure to communicate with the first control chamber, creating a pressure difference that enables detection of membrane failures while still allowing effective pressure transmission during normal operation.
Solution Approach 2:
The non-sealed mechanical coupling provides a feedback mechanism: under normal conditions, the pressure difference across the coupling maintains proper valve operation. When a membrane fails, the feedback changes (e.g., through audible leakage or pressure changes), promptly alerting operators to the fault while the valve continues to function with reduced performance.
3Reliability
If compressed air is used to actuate the valve, then the valve operation is reliable, but the air may break the flexible container and cause spillage
Solution Approach 1:
The dual-membrane system acts as an intermediary protective barrier between the compressed air actuator and the flexible container. The membranes transmit the necessary pressure for reliable valve operation while preventing direct contact between the compressed air and the container. Even if one membrane fails, the second membrane continues to provide protection against container rupture.
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 valve design ensures consistent operation by preventing pressurized air from causing container rupture, promptly alerts operators to faults, and minimizes machine downtime.
Implementation Method 1
The valve (19) comprises a first deformable membrane (28) and a second deformable membrane (24), arranged in series between a pneumatic actuator and a flexible container (3), for deformable driving of a shut-off system
Implementation Method 2
The valve (19) comprises a first deformable membrane (28) and a second deformable membrane (24)
Implementation Method 3
arranged in series between a pneumatic actuator and a flexible container (3), for deformable driving of a shut-off system. The valve (19) is provided with a non-sealed mechanical coupling between a first shell (12) and a second shell (13)
Data Source
AI summary
A pneumatically actuated valve includes a valve body, an inlet duct connected to the valve body and an outlet duct connected to the same valve body, a shut-off valve acting to selectively interrupt or allow the connection between the inlet duct and the outlet duct, a control chamber associated with the valve body and includes a first deformable membrane and a second deformable membrane which are adapted to form a flexible wall delimiting a closed, sealed space inside the control chamber and which operate on the shut-off valve. The valve further includes a spacing element interposed between the first deformable membrane and the second deformable membrane to define an intermediate chamber between the first deformable membrane and the second deformable membrane, the intermediate chamber being without fluid sealing.