Pressure Regulator with Dual Valve Elements and Diaphragm Vent
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Solution Overview
Problem
Miniature pressure regulators for medical devices face challenges such as 'pressure droop' and increased outlet pressure due to diaphragm leaks, where the pressure at the regulator outlet deviates from the set point and can rise significantly if a leak path occurs, compromising performance and accuracy.
Innovation Solution
A pressure regulator design featuring a resilient diaphragm with a vent aperture, a closure member with upstream and downstream valve elements, and a deflection member to reduce pressure droop and limit outlet pressure in case of diaphragm leaks, using a combination of valve elements and a Venturi effect to maintain regulated pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the pressure regulator is reduced to meet miniaturization requirements, then portability and convenience are improved, but flow capacity is reduced and pressure droop increases
Solution Approach 1:
The closure member is divided into two separate valve elements (upstream and downstream), each controlling different aspects of flow. This segmentation allows independent optimization of pressure control and flow capacity within a compact design.
Solution Approach 2:
The downstream valve element utilizes the vertical dimension by extending below the aperture plane, creating a three-dimensional flow control structure. This allows flow restriction without increasing the horizontal footprint of the regulator.
2Volume of moving object
If the size of the pressure regulator is reduced to meet miniaturization requirements, then portability and convenience are improved, but outlet pressure stability deteriorates due to increased pressure droop
Solution Approach 1:
The downstream valve element provides preliminary flow restriction before the main upstream valve element. This pre-restriction stabilizes pressure by controlling flow characteristics in advance, reducing the magnitude of pressure droop that occurs during operation.
Solution Approach 2:
The downstream valve element acts as an intermediary between the inlet and the upstream valve element, mediating flow characteristics. This intermediate control stage prevents direct, uncontrolled flow variations from affecting outlet pressure stability.
3Ease of manufacture
If a significant leak path occurs in the regulator diaphragm, then manufacturing simplicity is improved, but outlet pressure control is lost and pressure rises well above set point
Solution Approach 1:
The downstream valve element provides a safety mechanism that activates when diaphragm failure occurs. It creates a predetermined flow restriction that limits maximum outlet pressure even when the upstream pressure control system fails due to diaphragm leaks.
Solution Approach 2:
The downstream valve element converts the potential harm of diaphragm failure into a beneficial safety feature. When diaphragm leaks cause uncontrolled pressure rise, the downstream element's flow restriction becomes the primary pressure-limiting mechanism, preventing dangerous pressure levels.
4Productivity
If the regulator is designed with higher flow capacity, then productivity is improved, but device complexity increases to maintain pressure accuracy
Solution Approach 1:
Both upstream and downstream valve elements are integrated into a single closure member component. This merging of functions into one piece reduces assembly complexity while providing dual-stage flow control for enhanced pressure accuracy at high flow capacities.
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 effectively limits outlet pressure in case of diaphragm leaks, maintains accuracy, and increases flow capacity while reducing manufacturing costs and complexity, providing a compact and reliable pressure regulation system.
Implementation Method 1
the housing comprises a resilient diaphragm in fluid communication with the fluid and in physical communication with the closure member such that the diaphragm is operable to deform in response to a change in pressure of the fluid and such that deformation of the diaphragm causes the closure member to change position
Implementation Method 2
the downstream valve element of the closure member is a ridge operable with an aperture in the valve seat housing to at least partially control fluid flow, wherein said ridge of the closure member is partially or fully inside said aperture in the valve seat housing
Implementation Method 3
the section of the diaphragm not in fluid communication with the channel, is in fluid communication with the exterior of the regulator via a vent aperture
Data Source
AI summary
A pressure regulator, said pressure regulator comprising a housing containing a channel arranged to communicate a fluid from a fluid inlet to a fluid outlet, said channel comprising a valve seat housing, a valve seat and closure member with said closure member operable with the valve seat and valve seat housing to control flow through the channel; wherein the housing comprises a resilient diaphragm in fluid communication with the fluid and in physical communication with the closure member such that the diaphragm is operable to deform in response to a change in pressure of the fluid and such that deformation of the diaphragm causes the closure member to change position, and; wherein the section of the diaphragm not in fluid communication with the channel, is in fluid communication with the exterior of the regulator via a vent aperture and; wherein the closure member comprises an upstream valve element and downstream valve element, wherein the downstream valve element is a ridge operable with an aperture in the valve seat housing to at least partially control fluid flow, wherein said ridge of the closure member is partially or fully inside said aperture in the valve seat housing when the upstream valve element of the closure member is at or between the fully open position and a predetermined partially open position with the valve seat, to provide a restriction to fluid flow but not to fully obstruct flow.