Membrane Valve Compression Fit Connection
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Solution Overview
Problem
Multi-piece membrane valves face issues with inconsistent connection quality and higher costs due to laser welding, as well as difficulty in achieving a flat top and bottom surface, which affects the performance and efficiency of compressors in refrigeration systems.
Innovation Solution
A membrane valve design utilizing a compression fit connection between the body and reeds or membranes, allowing for the use of different materials and manufacturing processes such as stamping or molding, which eliminates the need for welding and ensures a uniform surface plane, reducing costs and improving service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is used to join the body and reeds, then the connection strength is improved, but the manufacturing cost increases and the surface flatness deteriorates
Solution Approach 1:
The patent replaces the thermal welding process (laser welding) with a mechanical interference fit system. The reed is inserted into a recess in the body, creating a mechanical connection through friction and geometric interlocking. This substitution eliminates the need for expensive laser welding equipment and operations while maintaining connection strength through properly designed interference fit geometry.
Solution Approach 2:
The patent extracts the welding operation from the manufacturing process entirely, removing the problematic step that causes both high costs and surface deformation. By designing a purely mechanical assembly method, the welding step is eliminated, allowing for cost-effective manufacturing and flat surface completion through separate finishing operations on the body and reed components.
2Strength
If laser welding is used to join the body and reeds, then the connection strength is improved, but the surface flatness deteriorates
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical interference fit system. The reed is inserted into a recess in the body, creating a mechanical connection through friction and geometric interlocking. This substitution eliminates the heat-affected zone and material deformation associated with welding, allowing both components to maintain their original flat surfaces while achieving strong mechanical connection.
Solution Approach 2:
The patent divides the valve into separate components (body and reed) that are assembled through interference fit rather than joined as a monolithic structure. This segmentation allows each component to be manufactured and surface-finished independently to precise flatness tolerances, then assembled without compromising the flatness of either surface.
3Strength
If different materials are used for the body and reeds, then the mechanical properties are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the material parameters of different components (body and reed) to optimize their mechanical properties. The body can be made from a harder, more wear-resistant material while the reed can be made from a more flexible material suitable for oscillation. The interference fit connection accommodates these different materials without requiring complex joining processes, as the mechanical press-fit can join dissimilar materials effectively.
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 compression fit connection enhances the consistency and quality of the membrane valve assembly, reduces manufacturing costs, and improves the mechanical resistance and flexibility of the components, leading to increased compressor efficiency and longer service life.
Implementation Method 1
The compression fit connection is formed by a plurality of compression connections. The compression fit connection is formed by inserting an extension member into a recess so that the extension member deforms elastically and irreversibly upon insertion into the recess.
Data Source
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AI summary
An improved membrane valve (100) and method for manufacturing such membrane valve (100). The improved membrane valve (100) can be used for transferring fluids or gases in hermetic or semi-hermetic compressors, including a method and system for manufacturing a membrane valve (100) and a membrane valve (100) with applications for use in several motors, particularly in hermetic or semi-hermetic compressors which use, as a refrigeration fluid, an appropriate type of gas thus promoting the refrigeration physical affect. A body (200) and a membrane (300) of the membrane valve (100) are produced from substantially thin metallic plates separately in accordance to an available process and can be subjected to rounding in order to eliminate live comers, and then juxtaposed thus composing the valve (100), with the above mentioned membrane (300) on one side, fitted to the body (200) which is fixed through a connection process and, on the other side, left free to oscillate.