Pressure Reducer Diaphragm Assembly for Leak-Resistant Stroke Control
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Solution Overview
Problem
Pressure reducers suffer from leakage due to axial movement of piston rods, leading to reduced functional accuracy, and existing diaphragm designs are either costly or have limited stroke length and fragility.
Innovation Solution
A pressure reducer assembly featuring a silicone diaphragm with a central hole diameter less than the piston rod's outer diameter, allowing radial stress-induced deformation and bistable buckling, which enhances stroke length and durability, and a cost-effective stamping process for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a radial lip seal diaphragm is used, then sealing is achieved, but axial movement of the piston rod causes grooves to form and leakage occurs over time
Solution Approach 1:
The patent employs a flexible diaphragm made of elastomeric material that replaces the rigid radial lip seal. This diaphragm is stretched over the piston rod and secured at its periphery, allowing it to flex and maintain sealing contact without forming grooves. The flexible nature of the thin film enables it to accommodate piston rod movement while maintaining seal integrity, thus resolving the contradiction between initial sealing effectiveness and long-term durability.
Solution Approach 2:
The diaphragm is designed to be dynamically adaptable to piston rod movement. By stretching the diaphragm over the piston rod and securing only its peripheral edge, the system allows the diaphragm to dynamically adjust its position and shape during operation, maintaining sealing contact without the rigid constraint that causes groove formation in traditional seals.
2Ease of operation
If roll diaphragm technology with U-shaped geometry is used, then axial motion is achieved, but larger diameters are required and manufacturing costs increase
Solution Approach 1:
The patent changes the geometric parameters of the diaphragm from a U-shaped configuration requiring large diameters to a flat circular configuration with a central aperture. This parameter change maintains the necessary axial motion capability while significantly reducing the diameter requirements and simplifying manufacturing. The flat diaphragm with aperture can be produced more cost-effectively through standard cutting and stretching processes.
3Strength
If flat diaphragms reinforced with fabric insert are used, then structural strength is improved, but stroke length is limited to 2 mm and assembly costs increase
Solution Approach 1:
The patent uses a simple flat diaphragm made of elastomeric material without fabric reinforcement. The inherent flexibility of the elastomeric material allows for greater stroke length compared to reinforced flat diaphragms. The material's elasticity enables larger deformations while maintaining structural integrity, thus achieving both strength and extended stroke capability.
Solution Approach 2:
The patent employs a simple, unreinforced diaphragm design that can be manufactured at lower cost. While individual diaphragms may have limited service life, their low manufacturing cost and ease of replacement make them economically advantageous. The simplified construction without fabric inserts reduces assembly complexity and manufacturing expenses.
4Ease of manufacture
If annular elastic diaphragm is axially clamped between parts, then mounting is achieved, but the connection is fragile and functionality is compromised
Solution Approach 1:
The patent uses the flexibility of the elastomeric diaphragm to achieve mounting without rigid clamping. The diaphragm is stretched over the piston rod and secured at its periphery, using its own elastic properties to maintain the connection. This flexible mounting method eliminates the fragile axial clamping between parts while maintaining reliable functionality.
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 improved diaphragm design reduces leakage, increases stroke length, and is cost-effective, maintaining accuracy and reliability over time with reduced maintenance needs.
Implementation Method 1
the outer diameter of the piston rod is greater than the diameter of the central hole of the diaphragm and the diaphragm is assembled over the piston rod
Implementation Method 2
allowing radial stress-induced deformation and bistable buckling, which enhances stroke length and durability
Implementation Method 3
The coil spring has a calibrated spring modulus and is placed at the periphery of the valve member. The coil spring acts on the valve member to counteract a force generated on the flange by a pressure of the liquid collected in a regulating chamber
Implementation Method 4
a force generated on the flange by a pressure of the liquid collected in a regulating chamber
Implementation Method 5
an elastic diaphragm and a coil spring placed at the periphery of the valve member
Data Source
AI summary
A pressure reducer assembly (100) includes a pressure reducer body (110) defining at least one pressure reducer chamber (120) along a central axis (X-X′). The pressure reducer chamber (120) includes an inlet section (122) and an outlet section (124) fluidly coupled with the inlet section (122). The pressure reducer assembly (100) further includes a spring-operated hollow piston rod (121) having a center (X) along the central axis (X-X′), a cylindrical inner peripheral surface comprising an inner diameter (A), and a cylindrical outer peripheral surface comprising an outer diameter (B). A diaphragm (128) made of elastic material is adapted to be operatively coupled with the piston rod (121). The diaphragm (128) includes a central hole (150) having a center (Y) along a central axis (W-W′) and a diameter (C). The pressure reducer assembly (100) is characterized in that, in an unmounted state, the outer diameter (B) of the piston rod (121) is greater than the diameter (C) of the central hole (150) of the diaphragm (128), whereas in a mounted state, the outer diameter (B) of the piston rod (121) is the same as the diameter (C) of the central hole (150) of the diaphragm (128), and the diaphragm (128) is assembled over the piston rod (121) so that the central axis (X-X′) of the piston rod (121) coincides with the central axis (W-W′) of the diaphragm (128).