Emitter Diaphragm Flow Control Eliminates Bonding
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Solution Overview
Problem
The existing emitter designs for drip irrigation require multiple costly processes such as chemical bonding and heat welding to assemble the flap and body, increasing production costs.
Innovation Solution
An emitter design where a flexible diaphragm part is integrated with the intake and pressure reducing channels, and a separate base is used to adjust the flow rate, eliminating the need for bonding or welding by using a simple joining process that allows the base to be placed in a housing part without additional attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flap is turned about the hinge and coupled to the body by chemical bonding and/or heat welding to form the pressure adjustment chamber, then the emitter can function properly, but the production cost increases significantly
Solution Approach 1:
The patent combines the flap and body into a single integrally molded piece, eliminating the need for separate assembly steps involving hinges, bonding, or welding. This merging of components directly reduces manufacturing complexity and cost while maintaining the pressure adjustment chamber formation capability.
Solution Approach 2:
The patent segments the pressure adjustment chamber formation from the component assembly process. By designing the chamber to be formed during the molding process itself rather than through subsequent assembly operations, it separates the chamber creation from mechanical assembly, thereby reducing production costs.
2Ease of operation
If multiple processes including turning the flap about the hinge and coupling by bonding/welding are performed, then the emitter assembly is complete, but the production time and complexity increase
Solution Approach 1:
The pressure adjustment chamber is pre-formed during the integrally molding process itself, before any assembly operations. This preliminary formation of the chamber eliminates the need for subsequent assembly steps to create the chamber, reducing both production time and process complexity.
Solution Approach 2:
Multiple functions (flap structure, body structure, and pressure adjustment chamber formation) are merged into a single integrally molded component, eliminating multiple separate manufacturing and assembly processes, thereby reducing production complexity and time.
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 reduces production costs by eliminating the need for bonding and welding processes while maintaining the ability to adjust the flow rate of irrigation liquid effectively.
Implementation Method 1
a diaphragm part (182) having flexibility and disposed away from the base (190), the diaphragm part being configured to approach the base (190) when the pressure of the irrigation liquid in the tube is exerted on the diaphragm part
Implementation Method 2
a pressure reducing channel part communicated with the intake part and configured to form a pressure reducing channel, the pressure reducing channel being configured to carry the irrigation liquid while reducing a pressure of the irrigation liquid
Data Source
AI summary
An emitter provided with: a water intake part that communicates with the interior of a tube when the emitter is joined to the tube; a pressure-reducing flow channel part for forming a pressure-reducing flow channel; a flow rate adjustment part for adjusting the flow rate of the irrigation liquid in accordance with the pressure of the irrigation liquid inside the tube; and a discharge part that faces a discharge opening. The flow rate adjustment part has: a base; an accommodation part that accommodates the base; a communication hole that opens to the base and communicates with the discharge part; and a diaphragm part that is flexible and is disposed so as to be separated from the base, the diaphragm part approaching the base when the pressure of the irrigation liquid inside the tube is received.