Dual Check Valve Gap Staging for Backflow and Grit Control
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Solution Overview
Problem
Existing IV check valves are susceptible to grit lodging, leading to leaks and backflows when reverse flow is applied, rendering them useless, and current infusion pumps are not reliable, cost-effective, or quiet enough.
Innovation Solution
A dual check valve system with an upper housing, intermediate housing, and lower housing, featuring first and second disks that selectively contact valve seats to create distinct gaps for fluid flow and backflow prevention, ensuring the first gap is smaller than the second gap to prevent particulate lodging and leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gap between the disk and the seat of the inlet port is made smaller to prevent grit lodging, then the reliability of the valve is improved, but the flow rate capability is reduced
Solution Approach 1:
The single valve is segmented into two separate check valves with distinct functions: the first check valve has a smaller gap optimized for preventing grit lodging and ensuring reliable sealing, while the second check valve has a larger gap optimized for maintaining adequate fluid flow rate. This segmentation allows each valve to specialize in one function without compromising the other.
Solution Approach 2:
The invention transitions from a single-dimension solution (one valve with compromise gap size) to a two-dimension solution (two valves in series with different gap sizes). By adding the dimensional aspect of having multiple valves with differentiated characteristics, the system can simultaneously achieve both small gap for reliability and large gap for flow rate capability.
2Device complexity
If a single check valve is used to maintain normal flow, then the device complexity is reduced, but the valve becomes susceptible to grit lodging causing leaks and backflows
Solution Approach 1:
The single check valve is segmented into two separate check valves with distinct functions: the first check valve handles normal forward flow with a smaller gap to prevent grit lodging, while the second check valve handles reverse flow prevention with a larger gap. This segmentation allows each valve to specialize in one function without compromising the other.
Solution Approach 2:
The first check valve acts as an intermediary that filters out grit and particulates before they can reach the second check valve. By placing this protective element in the flow path, the system prevents grit from lodging in the second valve's larger gap, thereby maintaining reliability without requiring complex additional filtering mechanisms.
3Productivity
If the gap between the disk and the seat is increased to improve fluid flow, then the productivity is improved, but the valve becomes more susceptible to grit lodging
Solution Approach 1:
The single valve is segmented into two separate check valves with distinct functions: the first check valve has a smaller gap optimized for preventing grit lodging and ensuring reliable sealing, while the second check valve has a larger gap optimized for maintaining adequate fluid flow rate. This segmentation allows each valve to specialize in one function without compromising the other.
Solution Approach 2:
The invention transitions from a single-dimension solution (one valve with compromise gap size) to a two-dimension solution (two valves in series with different gap sizes). By adding the dimensional aspect of having multiple valves with differentiated characteristics, the system can simultaneously achieve both small gap for reliability and large gap for flow rate capability.
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 dual check valve system effectively prevents backflow and particulate lodging, ensuring reliable and efficient fluid delivery while being more cost-effective and quieter than existing systems.
Implementation Method 1
when the fluid flows through the IV set, the flow pressure from the fluid movement deflects the disk and creates a gap between the disk and the seat of the inlet port allowing the fluid to flow through the check valve
Implementation Method 2
the first disk deflects away from the first valve seat to create a first gap between an upper surface of the first disk and the first valve seat
Implementation Method 3
when there is no movement of fluid, the disk in the chamber sits against the seat of the inlet port so that the check valve is sealed
Data Source
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AI summary
A dual check valve includes an upper housing, an intermediate housing, and a lower housing, and a first valve seat. The intermediate housing is coupled to the upper housing to define a first cavity, and includes a second valve seat. The lower housing is coupled to the intermediate housing to define a second cavity. A first disk is mounted in the first cavity and configured to selectively contact the first valve seat. A second disk is mounted in the second cavity and configured to selectively contact the second valve seat. When the dual check valve is in an open state, the first disk deflects away from the first valve seat to create a first gap, and the second disk deflects away from the second valve seat to create a second. The first gap is smaller than the second gap.