Hinged Cover Drip Emitter With Integrally Molded Membrane
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing drip emitters require multiple components and assembly steps, increasing production costs and complexity, particularly in pressure-regulated designs that often use different materials like plastic bodies and elastic membranes.
Innovation Solution
A single-part drip emitter design featuring a plastic frame and an elastomeric membrane, both formed by injection molding, where the membrane is integrated within the frame to create a pressure-regulating chamber, reducing assembly requirements and material complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components are used for pressure-regulated drip emitters (plastic body and elastic membrane), then pressure regulation function is achieved, but production cost and assembly complexity increase
Solution Approach 1:
The patent combines the plastic frame and elastomeric membrane into a single integrated component formed by injection molding. The membrane is molded directly within the frame structure, eliminating the need for separate assembly steps and reducing production complexity while maintaining the pressure regulation function.
Solution Approach 2:
The single-part design performs multiple functions: the frame provides structural support while the integrated membrane provides pressure regulation. This multi-functional integration reduces the number of components needed and simplifies manufacturing without compromising performance.
2Adaptability or versatility
If multiple components are used for drip emitters, then material properties can be optimized, but manufacturing cost and assembly steps increase
Solution Approach 1:
The patent uses composite materials by combining plastic and elastomeric materials in a single injection molding process. The first material forms the frame structure while the second material forms the membrane, allowing optimization of material properties for each function while maintaining a unified manufacturing process.
Solution Approach 2:
The injection molding process is designed to form both the frame and membrane in a predetermined sequence within a single manufacturing operation. The first material is injected to form the frame, then the second material is injected to form the membrane integrated within the frame structure.
3Manufacturing precision
If separate assembly steps are used for attaching membrane to frame, then proper positioning is achieved, but production time and complexity increase
Solution Approach 1:
The manufacturing process merges the formation of the frame and membrane into a single injection molding operation. The membrane is molded directly in its final position within the frame structure, eliminating separate positioning and attachment steps while ensuring precise placement.
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 solution enables a cost-effective, simplified manufacturing process for drip emitters with improved pressure regulation, reducing material inconsistencies and assembly steps while maintaining effective pressure control across a range of irrigation pressures.
Implementation Method 1
a membrane, preferably an elastomeric membrane, both formed by injection molding
Implementation Method 2
The frame and membrane are configured to cover at least a portion of the emitter body, when the emitter is in an operative assembled state
Data Source
AI summary
A drip emitter includes a frame, that can be made of plastic, and a membrane, that can be elastomeric; and both the frame and the membrane are formed by injection molding and are attached to each other.