Multi-Diaphragm Pump Layout for Low-Noise Air Pressure Delivery
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Solution Overview
Problem
There is a need for an effective way to generate air pressure to power pneumatic devices such as lumbar supports and massage assemblies, which existing diaphragm pumps may not adequately address in terms of noise, vibration, and size efficiency.
Innovation Solution
A pump assembly with a housing, motor, and multiple diaphragms arranged in non-co-planar planes, actuated by a central crank shaft, which minimizes noise and vibration while providing high pumping capacity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple diaphragms are arranged in non-co-planar planes with independent phase setting, then noise and vibration are minimized, but device complexity increases
Solution Approach 1:
The pump is divided into multiple diaphragm chambers (at least two diaphragms) arranged in non-co-planar planes, each capable of independent reciprocating motion. This segmentation allows each diaphragm to operate in slightly different phases, distributing the noise and vibration sources spatially and temporally, thereby reducing overall harmful effects while maintaining pumping functionality.
Solution Approach 2:
The diaphragms are configured to reciprocate in a periodic manner with independently adjustable phases. By setting different phase angles for each diaphragm's reciprocating cycle, the system creates a staggered operation pattern where peak noise and vibration events from one diaphragm are offset by others, minimizing the cumulative harmful effects over time.
2Productivity
If multiple diaphragms reciprocate to produce four air pulses per revolution, then pumping capacity increases, but device complexity increases
Solution Approach 1:
The pumping function is segmented across multiple diaphragms, with each diaphragm contributing to the overall air delivery. By arranging diaphragms in non-co-planar planes and configuring them to produce staggered air pulses (achieving four pulses per revolution), the system distributes the pumping workload, increasing total capacity while the modular segmented structure helps manage the inherent complexity.
Solution Approach 2:
The multiple diaphragms are phased to create overlapping and continuous air delivery cycles. As one diaphragm completes its discharge stroke, another is already preparing or executing its discharge, ensuring continuous useful action and maximizing pumping capacity utilization throughout each rotation cycle, thereby justifying the increased device complexity through enhanced productivity.
3Object-generated harmful factors
If diaphragms are positioned in non-co-planar planes, then vibration is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The diaphragms are deliberately positioned in non-co-planar planes rather than symmetric coplanar arrangements. This asymmetric spatial configuration ensures that vibration vectors from each diaphragm do not align and reinforce each other,而是 partially cancel out. The asymmetric design reduces overall vibration while the patent acknowledges the need for precise manufacturing to achieve the specified phase relationships and spatial positioning.
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 pump assembly achieves reduced noise and vibration, high pumping capacity, and compact size, making it suitable for applications like automotive and aerospace where these factors are critical.
Implementation Method 1
a crankshaft coupled to the drive shaft for co-rotation with the drive shaft about the drive shaft axis, a first connecting rod coupled to the crankshaft and to the first diaphragm, the first connecting rod configured to reciprocate along a first connecting rod axis in response to rotation of the crankshaft
Data Source
AI summary
A pump assembly includes a housing with an air inlet and an air outlet, a motor supported by the housing, the motor including a drive shaft rotatable about a drive shaft axis, a first plurality of diaphragms supported by the housing, the first plurality of diaphragms positioned along a first plane, and a second plurality of diaphragms supported by the housing, the second plurality diaphragms positioned along a second plane, the second plane spaced apart from the first plane. Rotation of the drive shaft is operable to move each diaphragm of the first plurality of diaphragms and each diaphragm of the second plurality of diaphragms from an intake position to a compression position to pump a fluid from the air inlet through the air outlet.