Rolling Diaphragm Pump Wrinkle Suppression via Rubber Overlay

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Solution Overview

Problem

Existing rolling diaphragm pumps for chemical solutions in semiconductor and organic EL device production face issues with wrinkles due to poor followability of synthetic resin diaphragms, leading to increased costs from decompression devices or surface modification treatments.

Innovation Solution

A rolling diaphragm pump design where a rubber layer is overlaid on the thin film portion of the diaphragm without adherence, with through holes for air discharge to prevent wrinkles and plastic deformation, maintaining an inexpensive configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a decompression device is used to bring the rolling diaphragm into close contact with the piston and housing, then the occurrence of wrinkles is suppressed, but the device complexity and cost increase

Engineering Contradiction:

Improvewrinkle suppressionVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A rubber layer is introduced as an intermediary component between the synthetic resin diaphragm and the piston/housing. This rubber layer has high elasticity and follows the reciprocation motion of the piston reliably, preventing wrinkles in the synthetic resin diaphragm without requiring complex decompression devices

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the material parameter of the diaphragm system by combining synthetic resin (for chemical resistance) with a rubber layer (for high elasticity and followability). This composite structure maintains the chemical resistance of the synthetic resin while adding the elastic followability of rubber to suppress wrinkles

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a rubber layer is adhered to the rolling diaphragm to suppress wrinkles, then the occurrence of wrinkles is suppressed, but the manufacturing cost increases due to surface modification treatment

Engineering Contradiction:

Improvewrinkle suppressionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The rubber layer serves as a mediator that can be overlaid on the synthetic resin diaphragm without requiring adhesion. The layer simply needs to be positioned over the diaphragm, and the elastic restoring force of the rubber layer suppresses wrinkles without needing chemical bonding

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The rubber layer can be designed as a simple overlay component that does not require complex bonding processes. This simplifies manufacturing and reduces costs compared to adhering rubber layers that require surface modification treatments

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If a rubber layer is overlaid on the thin film portion without adhesion, then the occurrence of wrinkles is suppressed with lower cost, but air may be trapped between the thin film portion and rubber layer causing plastic deformation

Engineering Contradiction:

Improvemanufacturing costVSAvoidplastic deformation prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The rubber layer is designed with through holes that create a porous structure. This allows air to escape from between the synthetic resin diaphragm and the rubber layer during reciprocation, preventing air entrapment that would cause plastic deformation of the thin film portion

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The rubber layer is segmented by creating through holes, which divides the continuous rubber material into regions separated by air passages. This segmentation allows trapped air to escape through the holes while the rubber layer continues to provide wrinkle suppression

Inventive Principle:

Principle #1Segmentation

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

Effectively suppresses wrinkles in the rolling diaphragm with a cost-effective solution by utilizing the rubber layer's restoring force and air discharge holes, enhancing the pump's operational reliability and reducing manufacturing costs.

Implementation Method 1

an external force that bends the bent portion becomes larger than an external force that causes wrinkles in a non-bent portion, due to the strong restoring force of the rubber layer to which tension is applied

Methodology Applied

Scientific EffectElastic restoring force: Elasticity

Implementation Method 2

A through hole for discharging air between the thin film portion and the rubber layer to the outside is preferably formed in the thin film portion

Methodology Applied

Scientific EffectAir discharge:

Data Source

PatentUS11668292B2Rolling diaphragm pump

Publication Date: 2023.06.06 NIPPON PILLAR PACKING CO LTD

AI summary

A rolling diaphragm 5 of a rolling diaphragm pump 1 has a movable portion 31 reciprocatable together with a piston 3, a fixed portion 32 fixed to a housing 2, and a thin film portion 33 connecting the movable portion 31 and the fixed portion 32 and bending due to reciprocation of the piston 3. A rubber layer 6 is overlaid on the thin film portion 33 without being adhered to the thin film portion 33, an end portion 6a on the movable portion 31 side of the rubber layer 6 is fixed to the piston 3, and an end portion 6b on the fixed portion 32 side of the rubber layer 6 is fixed to the housing 2.