Thin Diaphragm Segmented Membrane and Connection Portion
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Solution Overview
Problem
Conventional diaphragms with thicknesses less than 0.5 mm face challenges in injection molding and bonding of connection portions, making it difficult to form thin diaphragms with integrated connection components.
Innovation Solution
A diaphragm with a membrane portion made of a chemically resistant material and a connection portion made from the same material, where the connection portion is formed by injecting a molten second material onto the membrane portion and machined to create a threaded interface, allowing for direct bonding and connection to another member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection molding is used to form a diaphragm with connection portion, then the diaphragm can be integrally formed, but it is difficult to form a diaphragm having a thickness of less than 0.5 mm
Solution Approach 1:
The diaphragm is divided into two parts: a thin membrane portion (0.05-0.5 mm thickness) and a connection portion. The membrane portion is formed by a first material while the connection portion is formed by a second material, allowing each part to be optimized independently for its specific function.
Solution Approach 2:
The membrane portion and connection portion are directly bonded together through material injection and fusion, creating an integrated structure that combines the thin membrane with the connection features in a single manufactured component.
2Ease of manufacture
If bonding is used to attach connection portion to thin diaphragm, then connection can be achieved, but difficulty is encountered in bonding to diaphragm having thickness of less than 0.5 mm
Solution Approach 1:
The material properties are changed by using a second material with different characteristics than the first material. The second material is designed to be bondable to the thin membrane portion while providing the necessary connection functionality, overcoming the bonding difficulties associated with thin diaphragms.
3Adaptability or versatility
If diaphragm thickness is reduced to improve deformation capability, then sealing performance improves, but difficulty in forming and bonding connection portion increases
Solution Approach 1:
By segmenting the diaphragm into membrane portion and connection portion made from different materials, the membrane can be optimized for thinness and deformation capability while the connection portion is optimized for manufacturability and bonding.
Solution Approach 2:
Different regions of the diaphragm have different material properties: the membrane portion uses a first material optimized for chemical resistance and flexibility, while the connection portion uses a second material optimized for bonding and structural integrity.
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
Enables the manufacturing of thin diaphragms with robust connection portions, improving durability and deformation capabilities while preventing particle generation and surface damage, with a deformation-to-diameter ratio of 0.15 to 0.25, enhancing the diaphragm's sealing and operational performance.
Implementation Method 1
the second material can be directly bonded to the membrane portion formed of the first material by injecting the second material in a molten condition onto the membrane portion
Data Source
AI summary
A diaphragm having chemical resistance is disclosed. The diaphragm includes a membrane portion and a connection portion which enables connection of the membrane portion to another member. The membrane portion is formed of a first material having chemical resistance. The connection portion is formed of a second material whose main material is the same as that of the first material. The membrane portion and the connection portion are directly bonded together.