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US-20260126036-A1 - SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM

US20260126036A1US 20260126036 A1US20260126036 A1US 20260126036A1US-20260126036-A1

Abstract

Described is a method for manufacturing a diaphragm assembly through the use of injection molding. The method can avoid the use of PTFE as a chemically resistant coating. Further, the method can increase overall adherence of a polymer diaphragm to an insert through the use of an interference surface on at least the surface of a head of the insert.

Inventors

  • Robert E. Gledhill, III
  • John T. Nguyen
  • Steve L. Smith

Assignees

  • Blue-White Industries, Ltd.

Dates

Publication Date
20260507
Application Date
20251008

Claims (5)

  1. 1 .- 33 . (canceled)
  2. 34 . A method of forming a diaphragm assembly, comprising: providing an insert having at least one of a tapped hole and a plurality of holes; placing the insert into a cavity in a mold; and using one of a screw and a ram charger to force polymer into the cavity and into at least one hole to surround the insert to form the diaphragm assembly.
  3. 35 . The method of claim 34 , further comprising cooling the cavity to solidify the polymer around the insert through one of water cooling, ice cooling and air cooling.
  4. 36 . A method of forming a diaphragm assembly, comprising: forming an insert having at least one of a tapped hole and a plurality of holes; placing the insert into a cavity in a mold; and using one of a screw and a ram charger to force polymer into the cavity and into at least one hole to surround the insert to form the diaphragm assembly.
  5. 37 . The method of claim 36 , further comprising cooling the cavity to solidify the polymer around the insert through one of water cooling, ice cooling and air cooling.

Description

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS This Application is a continuation of U.S. patent application Ser. No. 17/650,971, filed Feb. 14, 2022, titled “SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM, which is a continuation of U.S. patent application Ser. No. 16/448,516, filed Jun. 21, 2019, titled ”SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM, which is a continuation of U.S. patent application Ser. No. 14/466,211, filed Aug. 22, 2014, titled “SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM,” which claims the benefit of U.S. Provisional Application No. 61/870,072, filed Aug. 26, 2013, titled “SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM,” U.S. Provisional Application No. 61/870,679, filed Aug. 27, 2013, titled “SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM,” U.S. Provisional Application No. 61/919,556, filed Dec. 20, 2013, titled “SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM,” and U.S. Provisional Application No. 61/875,308, filed Sep. 9, 2013, titled “SEALING DIAPHRAGM AND METHODS OF MANUFACTURING SAID DIAPHRAGM,” the entirety of each of which is incorporated herein by reference. BACKGROUND Field The present disclosure relates generally to diaphragm assemblies for an aqueous solution, and methods for manufacturing said diaphragm assemblies. SUMMARY Disclosed herein are embodiments of a method for manufacturing a diaphragm assembly comprising forming an insert having a head and a body, wherein the head is located at one end of the body, forming at least one interference surface on the insert, disposing the insert within a cavity configured for injection molding, wherein at least the head is completely disposed within the cavity, and injection molding a polymer onto the insert, wherein the polymer is configured to adhere to the head and the interference surface of the insert. In some embodiments, forming the at least one interference surface can comprise forming the at least one interference surface at approximately the center of the head of the insert. In some embodiments, forming at least one interference surface can comprise forming a plurality of interference surfaces on the head of the insert. In some embodiments, forming at least one interference surface can comprise tapping at least one hole into the head of the insert to form a blind tapped hole. In some embodiments, the head can have a diameter greater than the diameter of the body. In some embodiments, at least five pairs of interference surfaces can be formed. In some embodiments, the interference surface can be located on the outside of the head. In some embodiments, the interference surface can comprise threads or grooves. In some embodiments, the polymer can be a PVDF polymer. In some embodiments, the PVDF polymer can comprise natural PVDF and KYNAR ULTRAFLEX® B. In some embodiments, the PVDF polymer can comprise 0.5% by weight natural PVDF and 99.5% by weight KYNAR ULTRAFLEX® B. In some embodiments, PTFE may not be used. Also disclosed herein are embodiments of a two part diaphragm assembly comprising an insert having a head and a body, wherein the head is located at one end of the body, at least one interference surface formed on the insert, and an injection-molded polymer diaphragm configured to at least partially surround the head of the insert and interfere with the interference surface. In some embodiments, the polymer can be semi-transparent. In some embodiments, the polymer can be transparent. In some embodiments, the interference surface can be located approximately at the center of the insert. In some embodiments, the insert can be metal. In some embodiments, the body of the insert can comprise a thread. In some embodiments, the interference surface can be a blind tapped hole. In some embodiments, the insert can further comprise at least one additional interference surface. In some embodiments, the additional interference surface can be configured as a through hole through the head. In some embodiments, the at least one interference surface can comprise at least five pairs of interferences surfaces. In some embodiments, the at least one interference surface can comprise four holes approximately equally spaced around the center of the insert and a fifth hole located at the center of the insert. In some embodiments, the interference surface can extend into the body. In some embodiments, the polymer diaphragm can form an air tight seal around the insert. In some embodiments, the polymer diaphragm can be a PVDF polymer diaphragm. In some embodiments, the PVDF polymer can comprise natural PVDF and KYNAR ULTRAFLEX® B. In some embodiments, the PVDF polymer can comprise 0.5% by weight natural PVDF, and 99.5% by weight KYNAR ULTRAFLEX® B. In some embodiments, PTFE may not be used. In some embodiments, the interference surface can have a rounded end. In some embodiments, the interference surface can be located on the outside of the he