Diaphragm valve formed using additive manufacture
An oscillating diaphragm valve is provided. The valve is configured such that, when the diaphragm is in a closed position, pressure of a fluid supply opens the valve, and when the diaphragm is in an open position, the pressure of the fluid closes the valve. The valve internals are formed as a single, enclosed piece, with openings provided only for supply and consumption. The pilot-operated diaphragm-type valve uses a return spring for the diaphragm that applies a biasing force to an outside surface of the valve internals. Additionally, an actuator is provided to selectively arrest the diaphragm in an open or closed position by applying force to a different outside surface of the valve internals.
1 . A valve, comprising:
an inner housing defining an internal space, the inner housing including a first orifice, a second orifice, and a flexible wall section;
a diaphragm within the internal space;
a main valve having a shaft that is connected to the diaphragm, wherein the diaphragm is movable between a closed position, in which the main valve prevents fluid flow between the first orifice and the second orifice, and an open position, in which the main valve permits fluid flow between the first orifice and the second orifice; and
an actuator configured to apply a force to the flexible wall section to cause the flexible wall section to contact the shaft of the main valve to selectively arrest the diaphragm in the closed position or in the open position.
2 . The valve of claim 1 , wherein the diaphragm divides the internal space into a first volume and a second volume, the valve comprising:
a return spring, external to the inner housing, wherein the return spring applies a force through the flexible wall section to bias against expansion of the diaphragm into the second volume.
3 . The valve of claim 1 , wherein the flexible wall section has a smaller thickness than a thickness at other sections of the inner housing.
4 . The valve of claim 1 , further comprising:
an outer housing providing a support structure to prevent distortion of walls of the inner housing by internal pressure.
5 . The valve of claim 1 , wherein the diaphragm divides the internal space into a first volume and a second volume, the valve comprising:
a pilot channel connecting the second volume to the second orifice; and
a pilot valve connected to the diaphragm,
wherein the pilot valve prevents fluid flow through the pilot channel when the diaphragm is in the open position, and
wherein the pilot valve permits fluid flow through the pilot channel when the diaphragm is in the closed position.
6 . The valve of claim 1 , wherein the inner housing, the diaphragm, and the main valve form a unitary structure.
7 . The valve of claim 1 , wherein the diaphragm comprises one or more bleed holes that permit fluid flow through the diaphragm.
8 . The valve of claim 1 , wherein the inner housing defines a substantially cylindrical internal space, and
wherein the diaphragm is axially aligned with a valve seat for the main valve.
9 . A method comprising:
forming, as a unitary structure, valve internals including:
an inner housing defining an internal space, the inner housing including a flexible wall section,
a diaphragm within the internal space, and
a main valve having a shaft that is connected to the diaphragm;
providing an actuator system that is configured to apply a force to the flexible wall section of the inner housing to cause the flexible wall section to contact the shaft of the main valve; and
applying a rigid outer housing over the inner housing and at least a portion of the actuator system.
10 . The method of claim 9 , wherein forming the valve internals comprises:
forming the valve internals using a fused filament fabrication (FFF)-based printing platform.
11 . The method of claim 9 , wherein forming the valve internals includes:
forming the inner housing and the diaphragm from a same material.
12 . The method of claim 9 , wherein forming the valve internals includes:
forming the inner housing and the diaphragm from different materials.
13 . The method of claim 9 , wherein the inner housing comprises an elastomeric material and wherein the rigid outer housing comprises a rigid material.
14 . The method of claim 9 , further comprising:
adding a return spring configured to exert a biasing force through the flexible wall section against the diaphragm.
15 . A valve system, comprising:
an inner housing defining an internal space, the inner housing including a first orifice, a second orifice, and a flexible wall section;
a diaphragm within the internal space;
a main valve having a shaft that is connected to the diaphragm, wherein the diaphragm is movable between a closed position, in which the main valve prevents fluid flow between the first orifice and the second orifice, and an open position, in which the main valve permits fluid flow between the first orifice and the second orifice;
an actuator configured to apply a force to the flexible wall section to cause the flexible wall section to contact the shaft of the main valve to selectively arrest the diaphragm in the closed position or in the open position; and
a rigid outer housing providing a support structure for the inner housing.
16 . The valve system of claim 15 , wherein the diaphragm divides the internal space into a first volume and a second volume, the valve system comprising:
a return spring, external to the inner housing, wherein the return spring applies a force through the flexible wall section to bias against expansion of the diaphragm into the second volume.
17 . The valve system of claim 15 , wherein the diaphragm divides the internal space into a first volume and a second volume, and the inner housing further includes:
a pilot channel connecting the second volume to the second orifice; and
a pilot valve connected to the diaphragm,
wherein the pilot valve prevents fluid flow through the pilot channel when the diaphragm is in the open position, and
wherein the pilot valve permits fluid flow through the pilot channel when the diaphragm is in the closed position.
18 . The valve of claim 1 , comprising a pin, wherein the actuator is configured to apply the force to the flexible wall section by pushing the pin against the flexible wall section.
19 . The method of claim 9 , wherein providing the actuator system comprises providing an actuator and a pin, wherein the actuator is configured to push the pin against the flexible wall section to apply the force to the flexible wall section.
20 . The valve system of claim 15 , comprising a pin, wherein the actuator is configured to apply the force to the flexible wall section by pushing the pin against the flexible wall section.