Membrane Valve Double Sealing for Particle Contamination
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Solution Overview
Problem
Conventional diaphragm valves experience particle shedding during ultrasonic welding, leading to residual particles that cannot be flushed out, which can contaminate fluid or gas flowing through the valve, posing challenges for sterile applications.
Innovation Solution
The membrane valve employs two independent seals: a mechanical seal formed by ring-shaped projections and a welded seal, with the mechanical seal arranged radially inside and the welded seal radially outside, ensuring that particles generated during welding are trapped and preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the membrane and valve body are welded together to form a sealed valve body unit, then the valve is sealed during transport and can be designed as a disposable unit, but particle shedding occurs during welding that cannot be flushed out and may contaminate the fluid flow
Solution Approach 1:
The sealing system is segmented into two independent seals: a welded seal for transport protection and a mechanical seal (clamp) for operational sealing. This segmentation allows the welded seal to remain sealed during transport while the mechanical seal prevents particle contamination during operation by providing an additional barrier that can be opened for flushing.
Solution Approach 2:
The mechanical seal acts as an intermediary element between the welded seal and the fluid flow. It provides an additional sealing layer that can be opened to allow flushing of particles generated during welding, while maintaining the integrity of the welded seal structure.
2Device complexity
If a single welded seal is used to seal the valve body unit, then the structure is simple, but particles generated during welding remain trapped inside and cannot be removed
Solution Approach 1:
The sealing function is divided into two separate sealing mechanisms: a welded seal for structural integrity and a mechanical seal (clamp) for particle exclusion. This allows particles to be trapped between the two seals during transport, but the mechanical seal can be opened to flush particles out during operation.
Solution Approach 2:
Different sealing qualities are applied at different locations: the welded seal provides permanent sealing at the valve body connection, while the mechanical seal provides removable sealing at the membrane clamp location. This local differentiation allows for both transport sealing and operational particle removal.
3Ease of manufacture
If the valve body and membrane are firmly connected by ultrasonic welding to form a disposable valve body unit, then cost-effectiveness and sterile treatment are improved, but particle output is generated that contaminates the flow
Solution Approach 1:
The sealing system is segmented into a welded seal for disposable unit integration and a mechanical seal for particle management. This allows the valve to maintain the benefits of disposable unit manufacturing while adding a particle removal capability through the mechanical seal that can be opened for flushing.
Solution Approach 2:
The sealing approach changes from a single permanent weld to a combination of permanent weld and removable mechanical seal. This parameter change in sealing methodology allows the valve to transition from purely disposable integration to a system that can be prepared for sterile operation by flushing out welding particles.
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
This double sealing mechanism guarantees a particle-free valve body unit, suitable for ultra-clean environments like pharmaceutical and food sectors, ensuring compliance with hygienic standards and preventing contamination during transport and operation.
Implementation Method 1
The valve body and the membrane are firmly connected to one another by ultrasonic welding to form a fluid-tight valve body unit
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a membrane valve (10), in particular for fluid media, having a valve body (20), a membrane (22), and a connecting piece (24) which can be actuated by a drive unit (14) to act on the membrane (22), wherein the valve body (20) and the membrane (22) are made of plastic, wherein two mutually independent seals (48,50) are provided for sealing the fluid medium with respect to the outside, in that the valve body (20) and the membrane (22) are welded to each other, and the membrane (22) is mechanically sealed between the drive unit (14), or an intermediate piece (18), and the valve body (20).