Emitter Film Flow Control for Irrigation Stability
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Solution Overview
Problem
Conventional trickle irrigation emitters face issues with assembling errors, material cost due to different materials used, and instability in discharge rate under varying supply pressures, necessitating a solution for stable discharge and reduced manufacturing costs.
Innovation Solution
An emitter design with a single material, comprising an intake part, a first channel, a flow rate control part, and a discharge part, where a flexible film seals a recessed surface to control flow rates based on tube pressure, formed through injection molding for reduced components and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the emitter is formed by assembling three components (joined member, disposed member, and diaphragm part), then the discharge rate can be controlled according to pressure, but assembling errors occur causing variation in operation and discharge rate
Solution Approach 1:
The patent merges multiple components into a single integrated emitter body made of elastic material. The intake part, first channel, flow rate control part, and discharge part are all formed as one piece through injection molding, eliminating the need for assembly of separate components and thereby preventing assembling errors that cause discharge rate variation.
Solution Approach 2:
The emitter is constructed from a single material (inexpensive elastic material such as polyethylene or polypropylene) throughout its entire structure, including the flow rate control part. This homogeneity eliminates material compatibility issues and simplifies manufacturing while maintaining the pressure-responsive flow control function.
2Reliability
If the diaphragm part is composed of expensive elastic material such as silicone rubber film, then the pressure-responsive flow control function is achieved, but material cost increases
Solution Approach 1:
The patent replaces expensive elastic materials like silicone rubber with inexpensive elastic materials such as polyethylene or polypropylene. The emitter body is designed to be a disposable component that can be easily manufactured through injection molding, eliminating the need for costly materials while maintaining functional performance.
Solution Approach 2:
The entire emitter is made from the same inexpensive elastic material, eliminating the need to source and assemble expensive specialized materials. This single-material construction significantly reduces material costs while achieving the required pressure-responsive flow control through the integrated elastic structure.
3Area of stationary object
If hundreds of emitters are disposed in one long trickle irrigation tube, then coverage is improved, but supply pressure must be increased causing unstable discharge rate
Solution Approach 1:
The emitter incorporates a dynamic flow rate control mechanism where the elastic body deforms in response to pressure changes. The flow rate control part includes a variable cross-section channel that automatically adjusts discharge rate based on supply pressure, allowing stable operation even when pressure varies along long irrigation tubes with multiple emitters.
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 emitter stabilizes discharge rates by controlling flow according to pressure and reduces manufacturing costs by integrating components, ensuring efficient irrigation and cost-effectiveness.
Implementation Method 1
a film (300) having flexibility and configured to seal the recessed surface part (242) to block communication between inside of the tube (110) and the recessed surface part (242)
Implementation Method 2
The intake part or the first channel reduces a pressure of the irrigation liquid
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
An emitter (120) includes a flow path from a water intake path (221), which is for taking in irrigation liquid within a tube, to a recessed part (251). This flow path includes a recessed surface part (242) closed, without contact, by a film (300). A channel (243) that forms a reduced pressure flow path included in the above flow path is formed on the surface of the recessed surface part (242). If the film (300) is pressed by the pressure of the irrigation liquid in the tube (110) and adheres to the recessed surface part (242), the flow rate of the irrigation liquid inside the emitter (120) is controlled to an amount that can pass through the channel (243).