Diffuser assembly

1. A diffuser assembly comprising:

a flexible diffuser membrane defining a perimeter edge bead along four edges; and

a diffuser body defining an underlying body portion underlying the flexible diffuser membrane, and a perimeter edge frame covering a covered portion of the perimeter edge bead;

wherein the perimeter edge frame defines an inside surface that conforms to an outside shape of the covered portion of the perimeter edge bead;

wherein the perimeter edge frame is integral to the underlying body portion;

wherein the underlying body portion describes an arc shape;

wherein the flexible diffuser membrane conforms to the arc shape of the underlying body portion when the diffuser assembly is not in use;

wherein the perimeter edge bead projects away from the underlying body portion.

2. The diffuser assembly of claim 1 , wherein the flexible diffuser membrane comprises an elastomer.

3. The diffuser assembly of claim 1 , wherein the flexible diffuser membrane is rectangular in a plan view.

4. The diffuser assembly of claim 1 , wherein the flexible diffuser membrane defines a plurality of perforations therethrough.

5. The diffuser assembly of claim 1 , wherein the perimeter edge bead is not substantially compressed by the diffuser body.

6. The diffuser assembly of claim 1 , wherein the diffuser body comprises a thermoplastic.

7. The diffuser assembly of claim 1 , wherein the diffuser body defines an opening underlying the flexible diffuser membrane.

8. The diffuser assembly of claim 7 , wherein the diffuser body defines a hollow-cylindrical straight-walled portion in gaseous communication with the opening.

9. The diffuser assembly of claim 7 , wherein the diffuser body defines a hollow-cylindrical internally-threaded portion in gaseous communication with the opening.

10. The diffuser assembly of claim 1 , wherein the arc shape of the underlying body portion has a curvature transverse to a longitudinal axis of the underlying body portion.

11. The diffuser assembly of claim 1 , wherein the perimeter edge frame defines a plurality of slots therein, each of the plurality of slots exposing a respective outside surface portion of the perimeter edge bead.

12. The diffuser assembly of claim 1 , wherein the covered portion of the perimeter edge bead consists of a majority of the perimeter edge bead.

13. A wastewater treatment system comprising:

a wastewater treatment tank defining a bottom;

a gas distribution pipe supported over the bottom; and

a diffuser assembly in gaseous communication with an inside of the gas distribution pipe and comprising:

a flexible diffuser membrane defining a perimeter edge bead along four edges; and

a diffuser body defining an underlying body portion underlying the flexible diffuser membrane, and a perimeter edge frame covering a covered portion of the perimeter edge bead;

wherein the perimeter edge frame defines an inside surface that conforms to an outside shape of the covered portion of the perimeter edge bead;

wherein the perimeter edge frame is integral to the underlying body portion;

wherein the underlying body portion describes an arc shape;

wherein the flexible diffuser membrane conforms to the arc shape of the underlying body portion when the diffuser assembly is not in use;

wherein the perimeter edge bead projects away from the underlying body portion.

14. The wastewater treatment system of claim 13 , further comprising:

a connection saddle comprising two hinged halves and a nipple;

wherein the nipple provides the gaseous communication between the inside of the gas distribution pipe and the diffuser assembly.

15. A method for forming a diffuser assembly comprising the steps of:

receiving a flexible diffuser membrane defining a perimeter edge bead along four edges; and

forming at least in part by injection molding a diffuser body defining an underlying body portion underlying the flexible diffuser membrane, and a perimeter edge frame covering a covered portion of the perimeter edge bead;

wherein the perimeter edge frame defines an inside surface that conforms to the covered portion of the perimeter edge bead;

wherein the perimeter edge frame is integral to the underlying body portion;

wherein, during injection molding, molten plastic directly contacts the covered portion of the perimeter edge bead.

16. The method of claim 15 , wherein the perimeter edge bead is supported by a plurality of supporting teeth during the injection molding.

17. The method of claim 16 , wherein:

the perimeter edge frame defines a plurality of slots therein, each of the plurality of slots exposing a respective outside surface portion of the perimeter edge bead; and

each of the plurality of slots is positioned where a respective one of the plurality of supporting teeth was located during the injection molding.