Dome-Loaded Pressure Regulator With Diaphragm-Ball Valve for Single Use
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Solution Overview
Problem
In bio-pharmaceutical manufacturing, there is a need to reduce overhead costs associated with cleaning and validation of sterile work environments, which existing pressure regulators do not adequately address due to complex designs and high material usage.
Innovation Solution
A pressure reducing regulator is designed using a ball as a valve element in conjunction with a diaphragm for pressure sensing, featuring a centerbody assembly with a valve chamber, outlet orifice, and a flexible control diaphragm bonded to the centerbody, allowing for efficient pressure regulation with minimal material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex pressure regulator design with multiple components is used, then pressure regulation functionality is achieved, but cleaning and validation costs increase
Solution Approach 1:
The patent combines the valve body, valve seat, and diaphragm into a single integrated regulator assembly that functions as one disposable unit. This merging of components eliminates the need for complex cleaning and validation of multiple separate parts, directly resolving the contradiction between achieving pressure regulation functionality and reducing cleaning/validation costs.
Solution Approach 2:
The invention implements a disposable pressure regulator designed for single-use applications. The entire regulator assembly is intended to be discarded after one use, eliminating overhead costs associated with cleaning and validation of sterile work environments. This directly addresses the contradiction by sacrificing device reusability to reduce operational costs and simplify compliance requirements.
2Reliability
If traditional pressure regulator components are used, then pressure control is achieved, but material usage and costs increase
Solution Approach 1:
The patent employs a diaphragm as a flexible membrane component to sense downstream pressure and actuate the valve. This thin-film approach replaces traditional rigid sensing mechanisms, reducing material usage while maintaining effective pressure control functionality. The diaphragm's flexibility allows for efficient force transmission with minimal material.
Solution Approach 2:
By designing the entire regulator as a disposable unit, the patent optimizes material selection for cost-effectiveness rather than long-term durability. This allows use of simpler, less expensive materials that would not be suitable for reusable applications, directly reducing material costs and usage while maintaining adequate pressure control for single-use scenarios.
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 overhead costs by simplifying the design, minimizing material usage, and enabling efficient pressure regulation, while maintaining sterility and compatibility with biochemical processes.
Implementation Method 1
a diaphragm for pressure sensing
Implementation Method 2
a flexible control diaphragm facing the process surface
Implementation Method 3
a spherical valve element disposed in the valve chamber and moveable between an open position in which it is spaced away from the valve seat, and a closed position in which it seals against the valve seat
Implementation Method 4
wherein a perimeter of the control diaphragm is bonded to the centerbody so as to define a seal that blocks the passage of fluid
Data Source
AI summary
A centerbody assembly for a pressure regulator includes: a centerbody having a process surface, at least one outlet orifice disposed in the centerbody; an outlet port positioned in fluid communication with the at least one outlet orifice; an inlet port; a valve chamber positioned in the centerbody in fluid communication with the inlet port, the valve chamber including a valve seat positioned in fluid communication with the process surface; a spherical valve element disposed in the valve chamber and moveable between an open position in which it is spaced away from the valve seat, and a closed position in which it seals against the valve seat; a flexible control diaphragm facing the process surface, wherein a perimeter of the control diaphragm is bonded to the centerbody so as to define a seal that blocks the passage of fluid; and wherein the valve element is mechanically interconnected with the control diaphragm.