Dual Membrane Pneumatic Valve for Food Processing
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Solution Overview
Problem
In ice cream and liquid/semi-liquid food product manufacturing machines, existing valves are prone to breaking under pressure, causing pressurized air to leak into flexible feeding containers, leading to product spillage and machine downtime due to wear or faulty operation.
Innovation Solution
A pneumatically actuated valve with a dual deformable membrane configuration, where the membranes are induction welded to the valve shells, creating a safety system that prevents pressurized air from reaching the containers, even if one membrane breaks, and allows for independent control of each valve to prevent spills and ensure continuous operation.
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 pressurized 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 pressurized 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 safety measure before pressurized air can reach the flexible container. The series arrangement of membranes provides a backup protection mechanism that cushions against the harmful effect of membrane failure.
2Power
If the valve is subjected to overpressure or sudden pressure changes, then the drive system may become more powerful, but the membrane may break allowing pressurized air to reach the flexible container
Solution Approach 1:
The dual membrane configuration provides advance protection against overpressure and sudden pressure changes. The series arrangement ensures that even if one membrane fails under high pressure, the second membrane still prevents pressurized air from reaching the flexible container.
Solution Approach 2:
The potential harmful effect of membrane breakage under pressure is converted into a safe condition by the series arrangement. If one membrane breaks, the system automatically prevents pressurized air from reaching the container, turning a potential failure into a safe state.
3Productivity
If pressurized air reaches the flexible container, then the container may burst causing product spillage, but this would require machine shutdown and cleaning
Solution Approach 1:
The dual membrane system provides preventive protection before pressurized air can reach the flexible container. By having two membranes in series, the system ensures that even if one membrane fails, the other still prevents container rupture and product spillage, maintaining continuous operation.
Solution Approach 2:
The potential harmful effect of container rupture is converted into a safe state by the dual membrane system. If one membrane breaks, the system automatically prevents pressurized air from reaching the container, eliminating the harmful effect of product spillage while maintaining productivity.
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 effectively prevents pressurized air from reaching the flexible containers, reducing the risk of spills and machine downtime, ensuring reliable operation and easy switching between feeding containers, thus maintaining hygienic conditions and productivity.
Implementation Method 1
the membranes are induction welded to the valve shells
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
In a machine (1) for making liquid or semi-liquid food products with a plurality of deformable feeding containers (3), each feeding container is connected to a processing chamber (5) for processing the base mixture and provided with a stirrer (6) and with thermal treatment means (7) for the base mixture, operating in conjunction with one another to convert the base mixture into a liquid or semi-liquid product. The connection of each feeding container (3) to the processing chamber (5) to connect it operatively to the processing chamber (5) and to transfer the base mixture from the feeding container (3) to the processing chamber (5) is made by means of a network (15) of withdrawing ducts (8) through an interposed pneumatically actuated valve (19) which can be activated and deactivated independently of the remaining valves (19) and which comprises a valve body (29) with an inlet duct (22) and an outlet duct (21), and with a shutter (20) acting to selectively interrupt or allow the connection between the inlet duct (22) and the outlet duct (21).