Double-Membrane Valve Structure for Detectable Membrane Failure
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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 compressed air from reaching flexible containers.
Innovation Solution
A pneumatically actuated valve with dual deformable membranes and a non-sealed mechanical coupling between shells, ensuring that if a membrane breaks, the pressurized air cannot reach the container, and the fault is immediately detectable, preventing spillage and allowing quick switching between containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single deformable membrane is used in the pneumatic valve, then the valve structure is simple, but the membrane may break under pressure causing compressed air to reach the flexible container
Solution Approach 1:
The single membrane is divided into two separate membranes (first deformable membrane and second deformable membrane) arranged in series. This segmentation ensures that if one membrane breaks, the other still prevents compressed air from reaching the flexible container, thus improving reliability while maintaining reasonable structural complexity.
Solution Approach 2:
The dual membrane system acts as a preventive measure against membrane failure. By having two membranes in series, the system provides a backup protection mechanism that cushions against the harmful effect of compressed air leakage before it can reach the flexible container.
2Stability of the object's composition
If membranes are sealed rigidly between shells, then the valve structure is stable, but membrane breakage is not detectable and causes product spillage
Solution Approach 1:
A non-sealed mechanical coupling is introduced as an intermediary between the first and second shells. This coupling allows the valve structure to remain stable during operation while enabling detection of membrane failures through air leakage, thus preventing product spillage by allowing operator intervention.
Solution Approach 2:
The non-sealed mechanical coupling provides a feedback mechanism where compressed air leakage indicates membrane breakage. This feedback allows the operator to detect faults immediately and take corrective action before product spillage occurs.
3Reliability
If the valve uses robust material and structure, then reliability improves, but the cost and complexity of the valve increases
Solution Approach 1:
Instead of using a single robust membrane, the system segments the protection function into two simpler membranes. This approach achieves higher reliability through redundancy rather than through material robustness, thereby avoiding increased complexity and cost associated with high-grade materials.
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 reliable valve system that maintains machine operation, prevents container burst, and allows swift container switching, reducing downtime and ensuring product integrity.
Implementation Method 1
a first deformable membrane (28) and a second deformable membrane (24), arranged in series
Implementation Method 2
first deformable membrane (28) and a second deformable membrane (24)
Implementation Method 3
non-sealed mechanical coupling between a first shell (12) and a second shell (13)
Implementation Method 4
pressurized air to drive the shut-off system
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A pneumatically actuated valve (19) comprises a valve body (29) an inlet duct (22) connected to the valve body (29) and an outlet duct (21) connected to the same valve body (29), shut-off means (7, 20) acting to selectively interrupt or allow the connection between the inlet duct (22) and the outlet duct (21), a control chamber (27) associated with the valve body (29) and including: - a first deformable membrane (28) and a second deformable membrane (24) which are adapted to form a flexible wall delimiting a closed, sealed space inside the control chamber (27) and which operate on the shut-off means (7, 20); the valve (19) comprising a spacing element (D) interposed between the first deformable membrane (28) and the second deformable membrane (24) to define an intermediate chamber between the first deformable membrane (28) and the second deformable membrane (24), the intermediate chamber being without fluid sealing.