Segmented Diffuser Housing for Injection-Molded Centrifugal Pumps
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Solution Overview
Problem
Conventional centrifugal pumps in dishwashers face manufacturing challenges due to the geometry of diffuser vanes, which prevents high-speed manufacturing and efficient fluid flow, leading to turbulence issues.
Innovation Solution
A diffuser housing assembly with a first diffuser housing portion featuring a groove and a second diffuser housing portion with an extrusion, allowing for the engagement and sealing of a diffuser vane, reducing recirculation and turbulence, and enabling injection molding for easier and more efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional diffuser vane geometries are used, then fluid flow efficiency is improved by reducing turbulence, but manufacturing complexity increases and high-speed manufacturing becomes impossible
Solution Approach 1:
The diffuser housing is segmented into multiple portions (first diffuser housing portion, second diffuser housing portion, etc.) that can be separately manufactured using injection molding and then assembled together. This segmentation allows each portion to be produced through high-speed manufacturing processes while maintaining the complex internal geometries needed for efficient fluid flow and turbulence reduction.
Solution Approach 2:
The invention changes the geometric parameters of the diffuser vanes to be compatible with injection molding processes. By modifying the vane geometries from conventional designs to those that can be formed through mold injection, the patent enables high-speed manufacturing while preserving the essential flow control functions. This includes adjusting curvature radii, thickness distributions, and angular orientations to match manufacturing capabilities.
2Reliability
If conventional diffuser vane geometries are used, then turbulence reduction is achieved, but production speed decreases due to manufacturing constraints
Solution Approach 1:
By dividing the diffuser housing into separable portions that can be independently injection molded, the invention enables parallel production of multiple components. This segmentation transforms a single complex manufacturing operation into multiple simpler, high-speed injection molding operations, dramatically increasing production speed while maintaining turbulence reduction performance through precise geometric control.
Solution Approach 2:
The invention replaces conventional mechanical manufacturing methods (such as CNC machining or manual forming) with injection molding technology. This substitution enables high-speed automated production of diffuser vanes with complex geometries, increasing productivity from manual/sequential processes to automated high-volume manufacturing while maintaining precise geometric tolerances for turbulence control.
3Productivity
If diffuser vanes are designed for high-speed manufacturing, then productivity increases, but fluid flow efficiency may deteriorate due to geometric simplifications
Solution Approach 1:
The invention optimizes geometric parameters of the diffuser vanes specifically for injection molding while maintaining fluid flow efficiency. This includes designing curvature radii, thickness profiles, and angular orientations that are both manufacturable through high-speed injection molding and effective at controlling fluid flow. The parameters are carefully selected to balance manufacturing constraints with hydrodynamic performance requirements.
Solution Approach 2:
The diffuser housing portions are designed with locally optimized geometries that address specific flow control requirements in different regions. Each portion can have tailored vane configurations, curvature variations, and thickness distributions optimized for its specific location in the fluid flow path, while all portions can be manufactured through the same high-speed injection molding process. This local quality approach maintains overall fluid flow efficiency despite standardized manufacturing methods.
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 reduces turbulence in fluid flow paths, enhances manufacturing efficiency by allowing high-speed production, and improves the performance of centrifugal pumps in dishwashers.
Implementation Method 1
a centrifugal pump in fluid communication with the wash chamber. The centrifugal pump includes a motor housing, a motor disposed in the motor housing, and a fluid impeller coupled to the motor
Implementation Method 2
The diffuser vanes are arranged within the centrifugal pump such that recirculation from the high pressure and lower pressure sides of the centrifugal pump is limited to reduce turbulence in the fluid flow paths
Implementation Method 3
The first diffuser housing portion includes a groove and the second diffuser housing portion includes an extrusion. A diffuser vane is positioned on the motor housing. The diffuser vane engages in the groove of the first diffuser housing portion. The extrusion of the second diffuser housing portion encloses the diffuser vane into the diffuser housing assembly
Data Source
AI summary
An appliance includes a tub defining a wash chamber, and a centrifugal pump in fluid communication with the wash chamber. The centrifugal pump includes a motor housing, a motor disposed in the motor housing, and a fluid impeller coupled to the motor. A diffuser housing assembly includes a first diffuser housing portion and a second diffuser housing portion. The first diffuser housing portion includes a groove and the second diffuser housing portion includes an extrusion. A diffuser vane is positioned on the motor housing. The diffuser vane engages in the groove of the first diffuser housing portion. The extrusion of the second diffuser housing portion encloses the diffuser vane into the diffuser housing assembly.