Integrated Filter Check Valve for Grit-Induced Backflow Leaks
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Solution Overview
Problem
IV check valves are susceptible to lodging grit and particulates, leading to leaks and backflows due to inadequate sealing during reverse flow, rendering them ineffective.
Innovation Solution
Integration of an elongated filter member with a maximized surface area upstream of the flexible valve member in the check valve, capable of withstanding backpressures and preventing the filter from collapsing, along with an axially extending stop to prevent displacement and ensure proper sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional check valve is used without a filter, then the device complexity is reduced, but the valve becomes susceptible to lodging grit and particulates which causes leaks and backflows
Solution Approach 1:
The patent combines the filter member and check valve into a single integrated assembly. The filter member is positioned upstream of the valve member within the same housing, allowing the system to simultaneously perform filtration and check valve functions without requiring separate components. This merging resolves the contradiction by maintaining reliability through integrated filtration while avoiding the complexity of separate filter and valve assemblies.
Solution Approach 2:
The integrated check valve assembly performs multiple functions: filtration of fluid, one-way flow control, and backflow prevention. The filter member removes particulates while the valve member prevents reverse flow, creating a multi-functional component that addresses both sealing reliability and operational versatility without requiring multiple separate devices.
2Reliability
If an elongated filter member with maximized surface area is integrated upstream of the valve member, then the filter effectiveness is improved, but the device complexity increases
Solution Approach 1:
The filter member is designed with an elongated configuration extending along the flow path, maximizing its surface area exposed to fluid flow. This dimensional extension allows the filter to effectively capture particulates without requiring a bulky or complex three-dimensional structure. The elongated form factor integrates smoothly within the valve housing while achieving superior filtration effectiveness.
3Reliability
If the filter member is positioned upstream of the valve member, then the filter prevents grit lodging at the valve seal, but the filter itself may collapse under backpressure
Solution Approach 1:
The filter member is constructed with a flexible yet structurally sound design that can withstand backpressure without collapsing. The filter medium is supported by a framework or housing structure that maintains its shape and porosity under reverse flow conditions, preventing collapse while allowing effective filtration. This resolves the contradiction by maintaining both seal integrity through proper filtration and structural strength under backpressure.
4Reliability
If the check valve is designed to be normally closed, then backflow prevention is improved, but the valve may not fully open during forward flow due to lodged particulates
Solution Approach 1:
The filter member is positioned upstream of the valve member to perform preliminary filtration of the fluid before it reaches the valve seal. By removing particulates and grit beforehand, the filter prevents contamination that could lodge at the valve seal and impede opening. This preliminary action ensures both reliable backflow prevention when closed and full flow capability when open, resolving the contradiction between sealing reliability and flow 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 integrated filter effectively prevents the passage of undesirable matter, maintaining valve functionality and preventing leaks and backflows, even under reverse flow conditions, thereby ensuring reliable fluid flow directionality.
Implementation Method 1
a filter member mounted in the upper housing upstream of the flexible valve member. The filter member has an elongated portion configured to maximize surface area thereof exposed to the fluid flow and restrict passage of undesirable matter in fluid flowing through the check valve
Implementation Method 2
a flexible valve member mounted in the cavity to selectively permit fluid flow in a first direction, and prevent fluid backflow in a second direction opposite to the first direction
Data Source
AI summary
A method of manufacturing a check valve may include forming an upper housing as cylindrical body with (i) an internal surface including an upstream internal surface and a downstream internal surface having a projection and (ii) an external surface, forming a T-shaped filter member and mounting the T-shaped filter member in the internal surface of the upper housing. The method may further include forming a lower housing with a support portion at a central portion thereof, mounting a flexible valve member on the support portion, and coupling the upper housing with T-shaped filter member mounted therein onto the lower housing with flexible valve member mounted therein such that the T-shaped filter member is disposed upstream of the flexible valve member.