Flow Washer Deformation for Pressure-Regulated Flow Control
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Solution Overview
Problem
Conventional flow regulators with flow washers are limited in maintaining a consistent fluid flow rate over a wide range of pressures, which is a challenge in applications like beverage dispensers that require precise water-to-syrup ratios.
Innovation Solution
A modular flow regulator system incorporating a flow washer with a regulator body that includes a diffuser assembly and adjustable components, allowing the flow washer to deform and maintain a desired flow rate by rotating and radially compressing to adjust the orifice size in response to pressure changes, while preventing over-deformation with flow washer stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional flow washer is used to regulate fluid flow, then the flow rate can be maintained over a limited pressure range, but the flow rate rapidly decreases when pressure exceeds the operating range
Solution Approach 1:
The flow washer is divided into multiple functional zones: a central orifice region for primary flow regulation, a radially outward extending deformable wall section for pressure-responsive area adjustment, and a circumferential edge portion for structural support. This segmentation allows different regions to perform specialized functions that collectively extend the operating pressure range while maintaining flow consistency.
Solution Approach 2:
The flow washer incorporates a radially outward extending deformable wall section that dynamically changes its configuration in response to pressure variations. As pressure increases, this deformable section flexes radially outward, effectively increasing the flow area to compensate for the central orifice reduction, thereby maintaining consistent flow rate across an extended pressure range.
2Reliability
If a ceramic flow regulator is used to maintain correct water to syrup ratio, then the flow rate can be regulated over a range of pressures, but the manufacturing cost increases
Solution Approach 1:
The flow washer is constructed from inexpensive elastomeric material that can be easily molded and replaced if needed. This elastomeric construction provides a cost-effective alternative to expensive ceramic flow regulators while achieving similar flow regulation performance through the deformable wall section that automatically adjusts flow area in response to pressure changes.
Solution Approach 2:
The flow washer utilizes changes in the physical parameters of elastomeric material under pressure to achieve flow regulation. The deformable wall section changes its geometric parameters (area, shape) in response to pressure variations, providing automatic flow control without the need for expensive ceramic components or complex mechanical adjustments.
3Reliability
If the flow washer orifice diameter is reduced to maintain flow rate at high pressure, then the flow rate consistency is improved, but the flow area decreases leading to rapid flow rate drop beyond operating range
Solution Approach 1:
The invention merges the central orifice flow path with the radially outward extending deformable wall section to create a composite flow area. The total effective flow area is the combination of the central orifice area and the annular area provided by the deformable wall section, allowing the system to maintain flow rate consistency even as individual areas change under pressure.
Solution Approach 2:
The flow washer effectively creates a composite flow path combining rigid central orifice structure with flexible deformable wall material. This composite approach allows the rigid central portion to provide stable baseline flow control while the flexible peripheral portion dynamically adjusts to pressure changes, maintaining overall flow consistency across a wider pressure range.
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 system effectively maintains a consistent fluid flow rate over a broader range of pressures, reducing manufacturing costs by replacing expensive ceramic regulators with a more affordable flow washer-based solution, and synchronizes flow rates between different fluid sources for precise ratios in beverage dispensing.
Implementation Method 1
The flow washer includes a plate disposed on a support wall... The flow washer distorts to different diameters under different pressure conditions. Specifically, the size of the diameter of the orifice reduces as the source pressure is elevated.
Implementation Method 2
the diffuser transports fluid from the orifice of the flow washer into the diffuser channel and the diffuser channel transports fluid into the circumferential channel
Data Source
AI summary
A flow regulator system includes a flow regulator placed within a fluid flow path to maintain fluid flow therethrough at a desired flow rate. The flow regulator includes a flow washer having an orifice therethrough and a regulator body that receives the flow washer. At fluid pressures between a first fluid pressure and a second fluid pressure, the flow washer rotationally deforms to decrease or increase the size of the orifice, thereby maintaining the desired flow rate. When fluid pressure is greater than or equal to the second fluid pressure, the flow washer contacts a portion of the regulator body to prevent further rotational deformation of the flow washer. In addition, the flow washer radially compresses or expands to increase or decrease the size of the orifice, thereby maintaining the desired flow rate.