Variable Orifice Valve With Diaphragm Seal for Precise Small-Flow Control
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Solution Overview
Problem
Current methods fail to precisely control and maintain the flow of gas and fluid, especially in systems with orifices smaller than 3 inches in diameter, where creating leak-proof adjustable orifice systems is challenging, particularly for hazardous and toxic substances.
Innovation Solution
An adjustable orifice system using a diaphragm or bellows with a longitudinally movable plunger and rod, allowing for precise control of the flow path without shutting down the system, and accommodating changes in pressure levels, while ensuring a leak-proof seal using non-metal or metal materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional adjustable orifice systems are used for small diameter applications (sub 3 inches), then flow control capability is reduced, but system complexity and difficulty of creating leak-proof systems increases
Solution Approach 1:
The system divides the orifice control function into separate components: a fixed orifice plate with pre-drilled holes and an adjustable plug with corresponding holes. This segmentation allows each component to be simpler while maintaining precise flow control capability through their combination.
Solution Approach 2:
The adjustable plug is positioned within the orifice plate housing, with the plug's holes aligning with the orifice plate's holes. This nested arrangement allows the adjustable component to be integrated within the fixed structure, reducing overall system complexity while enabling precise flow control.
2Ease of operation
If traditional adjustable orifice systems are used for hazardous and toxic substances, then flow control is possible, but leak-proof reliability deteriorates
Solution Approach 1:
The adjustable mechanism is extracted to a separate plug component that can be independently sealed within the housing. This separation allows the orifice plate to maintain a fixed, reliable seal while the adjustable plug provides flow control capability through its own sealing interface.
Solution Approach 2:
The orifice plate is pre-configured with fixed holes and sealing surfaces before assembly. This preliminary preparation ensures that the critical sealing interfaces are established before the adjustable plug is installed, enhancing leak-proof reliability for hazardous substances.
3Measurement precision
If orifice size is reduced to increase precision, then flow control precision is improved, but system reliability deteriorates due to difficulty in creating leak-proof systems
Solution Approach 1:
The system separates the precision orifice function (fixed plate with precisely drilled holes) from the adjustment function (plug with alignable holes). This segmentation allows the orifice plate to be manufactured with high precision for micron-level openings while maintaining reliable sealing surfaces.
Solution Approach 2:
The orifice plate is pre-manufactured with precise hole patterns and sealing surfaces before assembly. This preliminary precision manufacturing ensures that even micron-level openings maintain reliable seals, while the adjustable plug provides flow control without compromising the pre-established precision interfaces.
Data Source
AI summary
An apparatus for controlling flow through a flow body comprising an intake opening and an output opening in the flow body, a cavity with a first cross-sectional shape and an opening, a diaphragm or a bellows, wherein the diaphragm or the bellows seals the opening of the cavity and the diaphragm or the bellows includes a hole, a plunger with the cross-sectional shape corresponding to the cavity, wherein the plunger is longitudinally movable within the cavity and a plunger portion forms an orifice with cavity portion, and a rod coupled with the plunger for facilitating the longitudinal movement of the plunger, wherein the rod comprises a rod cross section that corresponds to the hole in the diaphragm or the bellows.