Valve Diaphragm Segmented Bonding for Durability
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Solution Overview
Problem
The existing 3-layered valve structure experiences durability issues due to the gradual exfoliation of the resin sheet from the substrate, leading to weakened bonding strength and reduced valve response upon repeated operation.
Innovation Solution
A valve design featuring a diaphragm member with a thin film central portion and a thicker outer edge section, fixed to the inner wall surface at multiple points, which increases the adhered area and enhances durability by distributing stress concentration, preventing the diaphragm member from being removed during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin sheet is laminated on the entire upper surface of the first substrate to form a 3-layered valve structure, then the valve can control fluid flow through diaphragm expansion, but the resin sheet gradually exfoliates from the substrate during repeated operation, weakening bonding strength and reducing valve response
Solution Approach 1:
The invention divides the bonding interface into multiple discrete bonding holes distributed across the diaphragm surface, rather than relying on a single continuous bonding interface. This segmentation allows stress to be distributed across multiple localized bonding points, preventing progressive exfoliation that occurs with continuous bonding interfaces under repeated operational stress.
Solution Approach 2:
The invention creates localized bonding regions at specific bonding holes rather than uniform bonding across the entire diaphragm surface. Each bonding hole provides a concentrated bonding point with optimized local adhesion properties, allowing the diaphragm to maintain flexibility while achieving strong localized attachment to prevent exfoliation during repeated operation.
2Ease of manufacture
If the resin sheet is bonded to cover a groove in the second substrate, then a flow path can be formed, but bonding strength between substrates weakens and exfoliation occurs during continued use
Solution Approach 1:
The bonding interface is segmented into multiple discrete bonding holes rather than a continuous bonded region. This segmentation maintains the structural integrity needed for flow path formation while distributing mechanical stress across multiple points, preventing the propagation of delamination that would occur with continuous bonding under repeated operational loads.
Solution Approach 2:
The invention transitions from a two-dimensional continuous bonding interface to a three-dimensional distributed pattern of bonding holes with depth. This dimensional change allows bonding to occur at multiple levels within the substrate structure, creating a more robust attachment that resists exfoliation while maintaining flow path functionality.
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 enhanced valve design improves durability and resistance to repeated operations by increasing the adhered area between the diaphragm member and the substrate, preventing breakage and maintaining effective fluid control.
Implementation Method 1
when the air pressure is stopped, the resin sheet is returned to its original flat shape by elasticity thereof
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
A valve (1) disposed at a flow path (21) includes: a substrate (10) having a first surface (10a) in which a hole (2) having an opening section is formed; and a diaphragm member (4) fixed to at least part of a wall surface (3a) of the hole (2) and in which at least a central portion (4p) has a thin film shape, wherein a flow of a fluid in the flow path (21) is controlled by deforming the diaphragm member (4).