Resin Emitter Flow Control via Pressure-Responsive Valve Groove
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Solution Overview
Problem
The existing trickle irrigation emitters are prone to assembling errors, have unstable discharge rates due to varying pressure, and are costly due to the use of multiple materials and components, particularly the expensive silicone rubber diaphragm.
Innovation Solution
An emitter design with a single, inexpensive resin material that includes an intake part, a pressure reduction channel, and a flow rate controlling part with a valve element and groove system that stabilizes discharge rate by adjusting to pressure changes, allowing for quantitative irrigation liquid discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an emitter is formed by assembling three components (joined member, disposed member, and diaphragm part), then the discharge rate can be controlled, but assembling errors occur causing variation in operation and discharge rate
Solution Approach 1:
The patent merges multiple components (joined member, disposed member, and diaphragm part) into a single integrated emitter body made of resin. The flow rate controlling part is formed as an integral structure within the emitter body, eliminating the need for separate assembly of multiple components and thereby preventing assembling errors that cause discharge rate variation.
Solution Approach 2:
The single resin emitter body performs multiple functions: it serves as the structural housing, the flow path container, and the flow rate controlling mechanism. The flow rate controlling part with the valve element and groove is formed directly in the resin material, making the emitter body universally responsible for both structural support and flow regulation.
2Manufacturing precision
If expensive elastic material such as silicone rubber film is used for the diaphragm part, then the flow rate can be controlled, but material cost increases
Solution Approach 1:
The patent replaces the expensive silicone rubber diaphragm with a flow rate controlling part made of inexpensive resin material. The valve element and groove structure, formed directly in the resin emitter body, provides flow rate control functionality without requiring costly elastic materials, thereby significantly reducing material costs.
Solution Approach 2:
The patent changes the material parameter from expensive elastic material (silicone rubber) to inexpensive resin material. The flow rate controlling part achieves the required elasticity and flow regulation function through the resin material's inherent properties and the groove geometry, eliminating the need for expensive elastic materials.
3Length of stationary object
If supply pressure of irrigation liquid is increased to reach plants in long tubes, then irrigation can be extended, but discharge rate of the emitter becomes unstable
Solution Approach 1:
The patent implements a dynamic flow rate controlling part with a valve element that automatically adjusts to pressure changes. When supply pressure increases, the valve element moves to reduce the flow area through the groove, maintaining stable discharge rate. This dynamic adjustment mechanism allows the emitter to function correctly in long tubes where pressure variations occur.
Solution Approach 2:
The flow rate controlling part provides automatic feedback control: the valve element responds to pressure changes by adjusting its position relative to the groove, thereby self-regulating the flow rate. This feedback mechanism ensures stable discharge rate regardless of supply pressure variations in long irrigation tubes.
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 emitter stabilizes irrigation liquid discharge rates and reduces manufacturing costs by using fewer components and a single material, ensuring consistent performance and cost-effectiveness.
Implementation Method 1
a film for pushing the valve element toward the valve seat by being bent under the pressure of the irrigation liquid in the tube or in the intake part such that the valve element sits on the valve seat
Implementation Method 2
a film for pushing the valve element toward the valve seat by being bent under the pressure of the irrigation liquid
Implementation Method 3
a pressure reduction channel for allowing the irrigation liquid received from the intake part to flow therethrough while reducing a pressure of the irrigation liquid
Data Source
AI summary
This emitter (120) includes a channel which spans to a recessed section (252), from an intake path (221) for receiving an irrigation liquid inside a tube. The channel includes an aperture (243) which is closed by a lid (244) disposed so as to not be in contact with a film (300). A groove is formed at the periphery of the aperture (243). When the film (300) is pressed as a result of the pressure of the irrigation liquid inside the tube, and the lid (244) closes the aperture (243), the flow rate of the irrigation liquid inside the emitter (120) is controlled so as to be the amount capable of passing through the groove. This flow-rate control continues until the pressure difference in the channel between a side upstream with respect to the lid (244) and a side downstream with respect to the lid (244) has been sufficiently reduced.