Elastic Suction Valve Structure for Compact Diaphragm Pumps
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Solution Overview
Problem
Existing diaphragm pumps with umbrella valves face challenges in achieving both cost reduction and size reduction due to manufacturing errors affecting seal surface accuracy and requiring costly cutting operations for knob portions.
Innovation Solution
A diaphragm pump design featuring at least one valve made of an elastic material, with a shaft and plate-shaped valve element, where the shaft is sandwiched between housing members to ensure precise contact with a seat surface, eliminating the need for a knob portion and enhancing seal surface accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the knob portion is left without being cut, then cost reduction is achieved, but the pump becomes bulky and other parts cannot be arranged at optimum positions
Solution Approach 1:
The invention removes the knob portion from the shaft structure entirely. The shaft is designed to be inserted directly into the housing member with the valve element forming the seal surface, eliminating the need for a protruding knob portion that would increase pump size while avoiding cutting operations that increase manufacturing cost.
Solution Approach 2:
Instead of having the knob portion protrude outward from the shaft, the invention inverts the approach by having the shaft fit into the housing member with the valve element sealing against the housing. This reverses the traditional umbrella valve structure where the knob portion would need to be cut to reduce size.
2Volume of moving object
If the knob portion is cut after assembly, then pump size is reduced, but cutting operations increase cost
Solution Approach 1:
The invention extracts and eliminates the knob portion from the design, so no cutting operations are needed. The shaft is designed to fit directly into the housing member with the valve element providing the seal, removing the need for post-assembly cutting that increases manufacturing cost.
3Ease of manufacture
If the valve element position is not constant due to manufacturing error, then assembly is easier, but seal surface accuracy and quality vary
Solution Approach 1:
The valve element is made of elastic material that automatically adjusts to maintain constant contact with the seat surface. The elasticity of the valve element compensates for manufacturing errors in the shaft or shaft holes, ensuring consistent seal surface accuracy without requiring precise assembly.
Solution Approach 2:
The invention changes the physical state of the valve element to an elastic material, allowing it to deform and adapt to manufacturing tolerances. This parameter change enables the valve element to maintain constant pressing force against the seat surface despite variations in shaft position due to manufacturing errors.
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
This design achieves high seal surface accuracy, reduces costs, and minimizes pump size by maintaining consistent pressing force despite manufacturing tolerances, thereby improving the sealing performance and operational efficiency.
Implementation Method 1
at least one valve of the suction valve and the discharge valve is made of an elastic material
Implementation Method 2
a second housing member configured to press the first end portion of the shaft inserted into the shaft hole toward the second end portion and hold the shaft together with the first housing member
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A diaphragm pump includes a suction valve configured to open and close a suction passage to a pump chamber. The suction valve is made of an elastic material and includes a shaft and a valve element. The upper end portion of the shaft includes a projection. A diaphragm holder includes a shaft hole in which the lower end portion of the shaft is inserted, and a seat surface to which part of the suction passage opens. A diaphragm housing presses the upper end portion of the shaft toward the lower end portion and holds the shaft together with the diaphragm holder. The valve element thus comes into tight contact with the seat surface.