High-volume diaphragm with geometrically enhanced reinforcement

Abstract

This invention is a high-volume large diaphragm which provides a pair of support sections specially configured to withstand the stresses implemented by an eccentrically actuated pushrod diaphragm pump. The pair of support sections is comprised of an interior support section and an exterior support section that are vertically offset relative to each other's placement on the wall of the high-volume large diaphragm. It is additionally anticipated that more than one pair of offset interior and exterior support sections can be provided on high-volume large diaphragms with significantly greater wall height.

Claims

1. A high-volume large diaphragm comprising a hat shaped structure, the hat shaped structure comprising: a. a wall; wherein the wall is shaped as a hollow frustum; the wall provides a first end with a first diameter and a second end opposite the first end and having a second diameter; the second diameter being greater than the first diameter; the wall including an exterior surface and an interior surface; b. a rim; wherein the rim is provided at the second end of the wall; the rim comprising a circular flange extending outwardly from the wall; c. a cap; wherein the cap is formed across the first end of the wall; and d. a pair of support sections; wherein the pair of support sections are formed on the wall; the pair support sections having a solid projection that protrudes from the wall; the pair of support sections comprising an exterior support section and an interior support section; the exterior support section protruding only from the exterior surface of the wall and not from the interior surface of the wall; the exterior support section protruding from the interior surface of the wall and not from the exterior surface of the wall; the exterior support section and the interior support section being vertically offset relative to each other.

2. The high-volume large diaphragm of claim 1, wherein the high-volume large diaphragm is actuated by an eccentrically driven pushrod.

3. The high-volume large diaphragm of claim 1, wherein the exterior support section is provided further from the rim relative to the interior support section.

4. The high-volume diaphragm of claim 1, wherein the interior support section is provided further from the rim relative to the exterior support section.

5. The high-volume diaphragm of claim 1, wherein the exterior support section is provided approximately equidistant from the interior support section and the cap.

6. The high-volume large diaphragm of claim 1, wherein each support section of the pair of circumferential support sections has a smoothly curved cross section shape formed by a series of three reverse curves of which the lower and upper reverse curves have an equal radii that are smaller than the radius of the middle reverse curve.

7. A high-volume large diaphragm comprising a hat shaped structure, the hat shaped structure comprising: a. a wall; wherein the wall is shaped as a hollow frustum; the wall provides a first end with a first diameter and a second end opposite the first end and having a second diameter; the second diameter being greater than the first diameter; the wall including an exterior surface and an interior surface; b. a rim; wherein the rim is provided at the second end of the wall; the rim comprising a circular flange extending outwardly from the wall; c. a cap; wherein the cap is formed across the first end of the wall; wherein the cap is attached to an eccentrically driven push rod; d. a pair of support sections; wherein the pair of circumferential support sections are unitarily constructed on the wall; the pair of support sections comprising a solid projection that protrudes from the wall; the pair of support sections including an exterior support section and an interior support section; each support section of the pair of support sections providing a smoothly curved cross section shape formed by a series of reverse curves; the exterior support section and the interior support section being vertically offset relative to each other; the exterior support section protruding only from the exterior surface of the wall and not from the interior surface of the wall; the interior support section protruding from interior surface and not from the exterior surface of the wall.

8. The high-volume large diaphragm of claim 7, wherein the high-volume large diaphragm is actuated by an eccentrically driven pushrod.

9. The high-volume large diaphragm of claim 7, wherein the exterior support section is provided furthest from the rim relative to the interior support section.

10. The high-volume diaphragm of claim 7, wherein the interior support section is provided further from the rim relative to the exterior support section.

11. The high-volume diaphragm of claim 7, wherein the exterior support section is provided approximately equidistant from the interior support section and the cap.

12. The high-volume large diaphragm of claim 7, wherein each support section of the pair of circumferential support sections protrude from the wall a distance equal to or less than one time of the wall thickness.

13. The high-volume large diaphragm of claim 7, wherein the series of reverse curves that defines the cross-section of each of the support sections are comprised of a lower and upper reverse curve that have equal radii that are smaller relative to the radius of the middle reverse curve.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top side view of a first exemplary reinforced high-volume large diaphragm; and

(2) FIG. 2 is a first perspective view of a section of a first exemplary reinforced high-volume large diaphragm; and

(3) FIG. 3 is a side view of a section of a first exemplary reinforced high-volume large diaphragm and an enlarged detail view of a pair of support sections on a first exemplary reinforced high-volume large diaphragm; and

(4) FIG. 4 is a perspective view of a second exemplary reinforced high-volume large diaphragm; and

(5) FIG. 5 is a perspective view of a section of a second exemplary reinforced high-volume large diaphragm; and

(6) FIG. 6 is a perspective view of a section of a third exemplary reinforced high-volume large diaphragm; and

(7) FIG. 7 is a side view of a diaphragm attached to a pushrod being eccentrically pulled in an upward motion; and

(8) FIG. 8 is a side view of a diaphragm attached to a pushrod being eccentrically pushed in a downward motion.

NUMBER REFERENCES

(9) 5, 6, 7 - - - High-Volume Diaphragm Pump 10 - - - Pair of Support Sections 10a - - - Exterior Support Section 10b - - - Interior Support Section 12 - - - Second Pair of Support Sections 12a Second Exterior Support Section 12b - - - Second Interior Support Section 15 - - - Plurality of rim ridges 20 - - - Wall 30 - - - Filleted edge 50 - - - Rim 60 - - - Cap 80,81 - - - Plurality of openings 90 - - - Plurality of cap ridges 95 - - - Alignments cutouts 100 - - - Pushrod 105 - - - Ring Plate

DETAILED DESCRIPTION

(10) A non-limiting embodiment of a high-volume large diaphragm has a pumping volume of at least 250 cubic inches. The high-volume large diaphragm features a hat shaped structure, which includes a wall 20 having a moderately thin-walled surface shaped as a hollow frustum. The wall 20 defines a first end with a first diameter and a second end opposite the first end and having a second diameter. The second diameter is greater than the first diameter. The wall 20 has an exterior surface and an interior surface. The vertical distance between the first end of the wall to the second end of the wall (i.e. the wall height) is at least three inches.

(11) The wall 20 includes structural features at the first end and the second end. A rim 50 is formed at the second end of the wall 20. The rim 50 is comprised of a circular flange extending outwardly from the wall. A cap 60 is formed across the first end of the wall 20. The cap 60 includes a plurality of openings 80, 81. The rim 50 and the cap 60 each include an upper surface and a lower surface. A plurality of concentric rim ridges 15 are formed on the upper surface and the lower surface of the rim 50. Also, a plurality of concentric cap ridges 90 are formed on the upper surface and lower surface of the cap 60.

(12) The wall 20 includes a pair of support sections 10. Each support section of the pair of support section 10 is comprised of a solid projection. Each support section of the pair of support sections is circumferentially continuous around the diaphragm wall. An exterior support section 10a is furthest from the rim 50 and protrudes only from the exterior surface of the wall 20 and not from the interior surface of the wall 20. An interior support section 10b is closest to the rim 50 and protrudes only from the interior surface of the wall 20 and not from the exterior surface of the wall 20. However, an alternative support section configuration is anticipated to provide the exterior support section 10a closest to the rim 50 and the interior support section 10b is provided furthest from the rim 50.

(13) It is anticipated that the high-volume large diaphragm comprises relative dimensions defining certain structural features. The thickness of the wall 20 of the high-volume large diaphragm is preferably about 0.170 inches to 0.150 inches, and a pair of support sections 10 that protrude from the wall 20 a distance not greater than one times the wall 20 thickness.

(14) Each of the circumferential support sections 10a, 10b has a smoothly curved cross section shape comprised of a series of reverse curves. The exterior support section 10a is further from the rim 50 relative to the interior support section 10b and protrudes only from the exterior surface of the wall 20 and not from the interior surface of the wall 20. The interior support section 10b is closer to the rim 50 relative to the exterior support section 10a and protrudes only from the interior surface of the wall 20 and not from the exterior surface of the wall 20. The interior support section 10b is located approximately at mid height of the wall 20. Each support section 10a, 10b respectively protrudes from the exterior and interior of the wall 20 a distance not greater than one times the wall thickness. The exterior support section 10a is located approximately mid height between the cap 60 and the interior support section 10b.

(15) Referring now to FIGS. 1 through 3, various views of a geometrically enhanced reinforced high-volume diaphragm 5 are provided. The high-volume diaphragm 5 is generally hat shaped, with a rim 50 at the nominal bottom, a cap 60 at the nominal top, and a wall 20 protruding from the rim 50 to the cap 60. A first filleted edge 30 provides a transition from the cap 60 to the top portion of the wall 20 and a second filleted edge provides a transition from the rim 50 to the bottom portion of the wall 20. The wall 20 has the shape of a hollow frustum. The angle of the wall 20 is a draft angle for molding. While it is anticipated that the diaphragm 5 is formed via an injection molding process that provides unitary construction of the diaphragm 5, it may also be integrally formed. The diaphragm 5 features a pair of vertically offset support sections 10, comprising an exterior support section 10a in the angled wall 20 and an interior support section 10b in the angled wall 20. As the high-volume large diaphragm 5 may be oriented other than as depicted, the top of the high-volume large diaphragm 5 or component thereof as shown in FIG. 2 is referred to as the nominal top, and, likewise, the bottom of the diaphragm or component thereof as shown in FIG. 2 is referred to as the nominal bottom.

(16) The support sections 10a, 10b are comprised of continuous circumferential areas of increased thickness along the wall 20 that smoothly transition from the wall 20 using a series of reverse curves. It is well known that a reverse curve is defined by a reversal of the concavity of the curve. The series of reverse curves are comprised of three reverse curves of which the upper and lower reverse curves have equal radii that are smaller relative to the radius of the middle curve. The detail view in FIG. 3 provides further illustrative reference to this dimensional relationship.

(17) The exterior of the diaphragm 5 is illustrated in FIGS. 2 and 3. The interior of the diaphragm is shown in FIGS. 1, 2, and 3. In use, the cap 60 is forced towards the rim 50, forcing fluid out of the interior space. The interior support section 10b is shown in FIGS. 1, 2, and 3. The arrangement of support sections 10a, 10b as shown in FIGS. 1 through 3 reduces rolling of the diaphragm wall 20 as the pushrod 100 traverses towards the diaphragm 5 and reduces wrinkling of the wall 20 as the pushrod 100 traverses away from the diaphragm 5. In other words, the reduction in mechanical strain from the pair of vertically off-set support sections 10 results in a reduction in alternating stresses.

(18) The pushrod 100 is attached to an eccentric sheave driven by the motor of the diaphragm pump. As the pushrod 100 rotates about the eccentric sheave its inclination varies which results in an eccentric force being applied to the high-volume large diaphragm 5. The eccentric force imparted on the high-volume large diaphragm 5 from the pushrod 100 creates additional stresses in the high-volume large diaphragm 5 that amplify the alternating stresses. The configuration of the pair of vertically offset support sections 10 optimally reinforce the walls of the high-volume large diaphragm 5 to resist these additional stresses resulting from the eccentrically driven pushrod 100.

(19) In the exemplary embodiment, the of the support sections 10a, 10b do not protrude from the wall 20 by more than one times the thickness of the wall 20. The thickness of the wall 20 of the exemplary diaphragm 5 is about 0.150 inches. The exterior support section 10a protrudes from the exterior surface of the wall 20 up to one times the thickness of the wall 20, preferably a maximum of about 0.5 to 0.6 times the thickness of the wall 20. The interior support section 10b protrudes from the exterior surface of the wall 20 up to one times the thickness of the wall 20, preferably a maximum of about 0.5 to 0.6 times the thickness of the wall 20.

(20) The rim 50 is a flange that extends peripherally outwardly (e.g., about 1 inch outwardly) at the base of the wall 20. A plurality of concentric shallow rim ridges 15 are formed on the top surface and bottom surface of the rim 50. The rim ridges 15 provide seals and improve the traction of the surfaces when the rim 50 is clamped for operation. A plurality of alignment cutouts 95 are provided in the free edge of the rim 50. When installed, the rim 50 is clamped between a mounting surface and a ring plate 105 (FIG. 7 and FIG. 8). Shanks of bolts 110 protrude through the ring plate 105 into the mounting surface. The alignment cutouts 95 align with the shank of each bolt 110, such that the shank protrudes through the concavity.

(21) Opposite the rim 50, a disc-shaped cap 60 extends from the narrower end of the wall 20. The interior surface of the wall 20 is visible in FIGS. 1, 2, and 3. The plurality of openings 80, 81 is provided in the cap 60. A plurality of concentric shallow cap ridges 90 are formed on the top surface and bottom surface of the cap 60. The cap ridges 90 provide seals and increased traction between abutting surfaces when the cap 60 is clamped to the pushrod 100 for installation.

(22) This invention is not limited to use with a particular pumping mechanism. However, the invention is optimally reinforced for use with a pumping mechanism that is comprised of a pushrod 100 that is positively connected to the diaphragm 5.

(23) In an embodiment, a diaphragm 5 is comprised of a thermoplastic elastomer (TPE), and more particularly a thermoplastic vulcanizate (TPV), and even more particularly Exxon Mobile Corporation's Santoprene TPV. Santoprene TPV is a dynamically vulcanized alloy comprised of cured EPDM rubber particles encapsulated in a polypropylene (PP) matrix. Santoprene TPV has been found effective for such a diaphragm 5, providing flexibility (elasticity and resilience) and acceptable structural integrity for long-term performance. Additionally, in a non-limiting exemplary embodiment, the diaphragm 5 is via injection molding.

(24) In another embodiment as shown in FIGS. 4 and 5, a diaphragm 6 further includes a rim 50 with a reduced plurality of alignment cutouts 95.

(25) In another embodiment as shown in FIG. 6, a diaphragm 7 is anticipated providing a pair of vertically offset support sections 10 and a second pair of vertically off-set ridges 12. Providing more than one pair of vertically offset support sections 10, 12 enhances durability of high-volume large diaphragms that have significantly greater wall height and prone to amplified stresses.

(26) While the embodiments of the invention have been disclosed, certain modifications may be made by those skilled in the art to modify the invention without departing from the spirit of the invention.