Liquid Pump Diaphragm Forming for Low Hydrocarbon Permeation

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Solution Overview

Problem

Existing fluid pumps face challenges in inhibiting gaseous emissions, particularly hydrocarbon emissions, due to permeation through diaphragms, which are not adequately addressed by current regulatory standards.

Innovation Solution

A method of forming a diaphragm involves clamping and plastically deforming a planar material to create a non-planar shape with an offset portion and sidewall, using materials like polyamides or metals, and incorporating multiple layers with vapor-permeation-resistant materials, along with vent chambers equipped with charcoal filters to adsorb hydrocarbons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a conventional planar diaphragm is used, then the manufacturing process is simple, but gaseous emissions (hydrocarbons) permeate through the diaphragm

Engineering Contradiction:

Improvegaseous emissionsVSAvoiddiaphragm structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent transforms the conventional planar diaphragm into a three-dimensional structure by adding an offset portion that protrudes into the fluid chamber. This dimensional change creates additional flow path length and turbulence, enhancing the diaphragm's ability to block gaseous emissions while maintaining manufacturing feasibility through stamping or forming processes

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent employs composite material construction by combining a diaphragm body made of elastomeric material with an offset portion that can be made of different materials or have different structural properties. This allows optimization of each portion for its specific function - the main diaphragm for flexibility and the offset portion for emission blocking

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If the diaphragm material is made thicker to reduce permeation, then emission inhibition improves, but the diaphragm flexibility and pumping efficiency deteriorate

Engineering Contradiction:

Improvevapor permeationVSAvoiddiaphragm flexibility

Core Design Contradiction:

Object-affected harmful factorsVSDuration of action of moving object

Solution Approach 1:

Instead of increasing thickness in the conventional direction, the patent adds a third dimension by creating an offset portion that extends into the fluid chamber. This approach increases the effective path length for vapor permeation without compromising the diaphragm's flexibility, as the offset portion acts as a barrier while the main diaphragm body remains thin and flexible

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent utilizes a thin-film diaphragm construction that maintains flexibility through appropriate material selection and thickness control, while the added offset portion provides the necessary barrier function against vapor permeation. This separates the flexibility function (handled by the thin main body) from the barrier function (handled by the offset portion)

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-affected harmful factors

If a non-planar diaphragm shape is formed to improve emission containment, then hydrocarbon adsorption improves, but the manufacturing complexity increases

Engineering Contradiction:

Improvehydrocarbon emissionsVSAvoidforming process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent creates a non-planar offset portion by extending the diaphragm material in the third dimension (into the fluid chamber), which can be achieved through conventional stamping, forming, or molding processes. This dimensional addition provides effective hydrocarbon containment without requiring complex multi-step manufacturing procedures

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The offset portion is pre-formed as an integral part of the diaphragm during the manufacturing process, rather than being added as a separate component. This preliminary formation of the emission-blocking structure in the initial manufacturing step simplifies production by eliminating subsequent assembly operations

Inventive Principle:

Principle #10Preliminary action

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 significantly reduces gaseous emissions by enhancing the diaphragm's structural integrity and incorporating vapor filters, ensuring efficient containment and adsorption of hydrocarbons, thereby meeting regulatory standards.

Implementation Method 1

vent chambers equipped with charcoal filters to adsorb hydrocarbons

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

plastically deforming the piece of material inboard of the clamped periphery

Methodology Applied

Scientific EffectPlasticity: Plasticity

Data Source

PatentUS12523213B2Method of forming a diaphragm for a liquid pump

Publication Date: 2026.01.13 OVERDRIVE ACQUISITION LLC

AI summary

In at least some implementations, a method of forming a diaphragm for a liquid pump, includes clamping a substantially planar piece of material about a periphery, and plastically deforming the piece of material inboard of the clamped periphery. In at least some implementations, the material is plastically deformed by pressing a forming member against the material, or the material is plastically deformed by applying a fluid under pressure against the material.