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Diaphragms
Technical Principles
Diaphragms 724
Products
Products 742
Diaphragms
Features
Application ranges
Basic Principles
Diaphragms made of elastic rubber materials have the The fundamental interrelationships can be best ex-
task of establishing a sealed and, at the same time, plained using the example of the pump or control
flexible partition between two component chambers diaphragms depicted in → Fig. 1.
and to enable volumetric changes of the separate
chambers.
Mode of operation and main dimensions
By virtue of their basic function, they can also be
characterised as flexible sealing components. The operating area of the diaphragm is restricted out-
wardly by the housing diameter and inwardly by the
In light of these prerequisites, a diaphragm can fulfil piston diameter. The diaphragm is statically fitted in the
3 main functions: housing and – if necessary – on the piston, to seal.
Located between the housing and piston there is a roll-
■ Controlling/switching function: ing gap, over which the flexed area of the diaphragm
hydraulic or pneumatic pressure applied to the is more or less tightly “stretched”. If there is a pressure
effective area of the diaphragm is transformed differential between the upper and lower side, then the
into a linear shaft force and operates a switching, flexed area is depressed into the rolling gap by the
controlling or display device. pressure load, initially taking on an arched form. As
■ Pump function: with a thin-walled pipe under internal pressure, pressu-
with the pump function, an introduced linear shaft rising forces and forces running tangential to the arch in
force or a hydraulic or pneumatic pressure on the the diaphragm wall are kept in balance.
effective area of the diaphragm is transformed into a The radius of the curve in the flexed zone is depend-
delivery pressure. ent on the length of the freely available surface line
between the clamping point on the housing and piston,
■ Separating function:
as well as the clearance between clamping point and
this function simply involves separating chambers
the position of the piston at the clamping plane. Con-
– which have virtually the same pressure level
sideration should be given to an adequate flexed zone
– from each other by means of a slightly movable
surface length when making the design.
and flexible partition. A good example of this are
When travelling through the stroke, the flexed area
applications in the area of accumulators.
"rolls" up in the rolling gap. When doing so, areas of
the diaphragm wall move from the piston to the housing
Diaphragms offer several advantages compared with
and vice versa, thereby undergoing an enlargement or,
contact seals:
respectively, reduction in diameter.
■ Leak-free
■ There is no requirement for lubrication,
Dg
therefore they are maintenance-free
P
■ No frictional losses
R
■ Minimal hysteresis with the appropriate constructive HO
design ρ R HU H g F
■ No breakaway force ("stick-slip effect")
■ Minimal wear due to clear roll-away movement b DK
DWU
■ Substantially reduced demands for tolerances and
DWO
surface quality of the adjacent components make
cost savings in component manufacturing possible.
Fig. 1 Main dimensions/mode of operation
P2
h
LO
∆I
Convoluted diaphragms
This design type (→ Fig. 5) involves a rolling convolu-
S
tion with an arched cross-sectional area, even in an un- h
S
h Hmax
Dm
DA
DA
P2
Dg
b Dm b
2 DK 2
b b Fig. 6 Long-stroke rolling diaphragms
P1
ρ
1H
2 max Diaphragms with fabric reinforcement
ρ Hmax All forms of diaphragms can be made as purely
P2 elastomer diaphragms or also with fabric reinforce-
ment. With these, the reinforcing fabric is embedded
in the middle of the diaphragm cross-section (insert)
Fig. 5 Convoluted diaphragms
or “placed upon” a surface (support). The support
must thereby always be on the non-pressurised side
Long-stroke rolling diaphragms
(e.g. outside of the rolling convolution), as otherwise
To be considered a special case amongst dished dia-
the elastomer layer would be separated from the fabric
phragms is the long-stroke rolling diaphragm (→ Fig. 6)
sheet by the pressure and the diaphragm would be
, which is everted during installation. With the design
destroyed.
with fabric reinforcement, the potential stroke is limited
It should be kept in mind that the very limited plasticity
by the deep drawing quality of the fabric.
of the fabric restricts its possibilities for usage from a
Rolling diaphragms must be supported on the outside
manufacturing-compatible point of view.
by the housing and on the inside by the piston. This
The different fabric types that can be used are ad-
provides for a quasi stroke-independent, constant ef-
dressed in more detail in → Diaphragm fabric page
fective diameter. Rolling diaphragms always require
739.
a pressure differential to the rolling convolution, as do
convoluted diaphragms, as otherwise they would be
Diaphragms with a support made of PTFE
everted by the pressure.
With aggressive ambient media and conveying media,
as can be found with pump applications, the chemical
resistance of the elastomer can be inadequate. In this
case there is the possibility of protecting the basic mate-
rial of the diaphragm by applying a foil made of PTFE
to protect the surface facing the medium, thus increas-
ing the service life.
Change of effective
Forms of diaphragms Max. stroke Hmax Applied pressure diameter Dw by means
of stroke H
8
T=20°C
7 Actuating pressure p
T=90°C
6
4 Effective area W
2
Stoke Hg
1
Diaphragm stroke H
Hg Hmax
Lifting pressure P
Design/Dimensioning
Operating data and boundary conditions approx. 10% to the regulating power and volumetric
The dimensioning of a diaphragm is essentially deter- displacement.
mined by the following operating data:
Step 2: Dimensioning of the diaphragm
■ The type of device (e.g. a cylinder operating under
With the dimensioning, the diaphragm and adjacent
rough operating conditions or a measuring device
components – such as the housing and piston – are
with high demands regarding inherent resistance
determined for the design engineering. When design-
and hysteresis)
ing the diaphragm, along with the strictly functional
■ Max. stroke with a subdivision in regard to the
aspect the manufacturing-compatible aspects must also
clamping plane
be considered. An examination and optimisation of all
■ Pressure (operating pressure and/or test pressure)
dimensions by the diaphragm manufacturer is recom-
■ Effective diameter (as a function of the stroke, if
mended in any case.
applicable)
The aspects listed below should be given particular
■ Ambient media
attention:
■ Operating temperature range
the values for Hmax apply in any case in for a symmetri-
■ Actuation frequency
cal distribution of the absolute stroke travel above and
■ Service life.
below the clamping plane, and they are:
When dimensioning the diaphragm it is recommended
[11] Hu max = Ho max = Hmax/2
to follow the procedure described below.
With an asymmetric stroke distribution, the absolute
Step 1: Select the design type according to
stroke travel Hg is thus always smaller than the maxi-
Tab. 1
mum possible stroke Hmax. In order to minimise the
Before selecting, the housing diameter Dg and dia-
bending stress and inherent resistance, the diaphragm
phragm stroke Hmax should be take from the operating
thickness s is generally made to be as thin as pos-
data. The ratios in the equations [7] through [10] are
sible. Here, however, in any case the specified limits
helpful in this regard:
of the material and manufacturing method must be
For a pump diaphragm the volumetric displacement can
observed. In general, it is recommended that fabric-free
be estimated with:
diaphragms are only utilised for pressures of less than
[7] V = π/4Dw2 Hg approx. 2 bar. With higher pressures, thin-walled, fab-
ric-reinforced diaphragms should be utilised instead.
The reciprocating force can be derived with:
[8] Fk = π/4 Dw2 p As a result of the uncoiling movement, bending stress
arises in the clamping area as well as in the flexed
Optimum usage of the diaphragm stroke can be area. In order to limit this loading to non-critical levels,
achieved with: clamping ribs and rolling fold areas should be chosen
for completely uncoiling diaphragms, dependent on the
[9] Hg = Hmax diaphragm thickness (→ Fig. 10).
In the first approach the correlation between housing [12] Clamping rib p ≥ 2 s
and effective diameter can be established [13] Rolling fold span b ≥ 6 s
(→ equation [6])
Attention should also be paid to the instructions on
[10] Dw = 0,85 Dg "Configuring the clamping and the contacting housing
parts".
As the stated relations only provide approximate
values, it is recommended to assign a safety factor of
Component stress
By applying Hooke’s Law for uniaxial state of stresses: The tensile strength σ´B of fabric is determined in tensile
trials as the maximum tensile force in regard to the sam-
[16] σ=Eε
ple width and can be enquired from the manufacturer.
By making use of a safety factor, consideration is given
... the elongation is derived for:
that the fibre direction around the periphery deviates in
[17] εp = p R/(s E) part from the direction (radial) of the stress.
In addition, with fabric the dependency of the tensile
Recommended values for the modulus of elasticity E are strength upon the operating temperature must be con-
stated in Fig. 7 . sidered.
Elongation due to
εp → b) ≤20%
internal pressure
R Design examples:
rolling diaphragms with fabric layer
In a control valve a rolling diaphragm is supposed to
S
be used according to the following boundary condi-
tions:
■ Housing-Ø Dg = 100 mm
■ Piston-Ø Dk = 90 mm
■ Pressure differential p = 10 bar ≈1 N/mm2
Fig. 12 Load stresses from a pressure differential The circumferential elongation as a result of the uncoil-
ing movement should be examined and the minimum
strength of the fabric determined:
Permissible load stress ■ From the geometry it can be deduced that:
b = (Dg–Dk)/2 = 5 mm
When assessing the load stress determined according R = b/2 = 2,5 mm
to the → component stress, a distinction must be made
between diaphragms with and without fabric reinforce- ■ With equation [14]:
ment. εu max= 0,11 = 11% ≤15% → i.O.
■ With equation [18]:
For fabric-free diaphragms under pressure load, in Fp/l = 2,5 N/mm
practical situations the specification of a maximum
■ From Tab. 2:
elongation has proven effective. This is founded upon
σ´B≥ Fp/l/0,2 = 12,5 N/mm
the structure of the elastomers, which are composed of
fibrous molecules that are interlaced with one another. The maximum circumferential elongation lies within the
permissible range, the minimum tearing resistance for
With fabric reinforced diaphragms the low percentage the fabric is 12,5 N/mm.
of contact area of the elastomers is disregarded and
it is assumed that the tensile stress is carried solely by
the fabric.
above 40 … 63 ± ±0,40 ± ±0,80 Tolerances that are closer than those previously stated
above 63 … 100 ± ±0,50 ±1,00 can be agreed upon, if necessary, depending on the
above 100 … 160 ± ±0,70 ±1,30
form and material of the desired diaphragms and after
corresponding production trials.
above 160 ±0,5% ±0,8%
Such agreements, which typically involve increased
Tab. 3 Diameter tolerance for moulded diaphragms production effort, should remain limited to unavoid-
able special cases, however (also refer to the notes in
The tolerances listed in the following, already restricted DIN ISO 3302 in this regard).
with regard to DIN ISO 3302-1, apply to the wall and
bead thicknesses of moulded diaphragms.
… 0,5 ±0,05
Depending on the usage, various materials can be ap- Determining the upper operating temperature of elasto-
plied. Thus, the material configuration of the elastomer meric material: A decisive value for the application of
to be used is contingent upon, for example, the physi- an elastomeric material is its pressure release behaviour
cal, thermal and chemical load stresses. Additional (→ Fig. 14). With regard to this, a reduction of the ten-
fabric reinforcement is also foreseen for higher loads. sion in a compressed state is presented as a function of
Depending on the type of pressure applied – unilateral time and temperature. The upper temperature operat-
or bilateral – and the form of the diaphragm to be pro- ing range limit is identified by this.
duced, it is designed with a fabric insert or layer.
Compressive stress relaxation
- gradients of TPE and elastomers -
Elastomers 100 EPDM/PP
90 ENR/PP
CR
Rel. compression stress [%]
80 NBR
When selecting suitable elastomer properties, the fol- 70
lowing characteristics stand in the foreground: Deformation: 25%
60 Temperature: 100°C
50 Medium: Air 2378 h/
■ For secure sealing of the clamping areas, the mate- 35,3%
40
rial should have a low pressure release values in 30 1/e = 36,9% 1708 h/
long-term tests. Service life 35,3%
20 1156 h/ 1946 h/
limit
■ The material should be sufficiently firm enough for 10 30% 33,3%
FK
M/
FFK
warm water, hot water and steam up to 130/140 °C.
VM ACM , Hu
M
210
Q
KTW (potable water) certifications, WRC and FDA
approval. Special qualities are available for use in the 190
EC
, E be r
PD
Operating temperature °C
M
foodstuffs industry. EPDM is not resistant to oil.
NB
R,
170
CR
FFKM – Perfluoro rubber (Simriz) 150
NR
Through the use of special perfluorated (i.e. completely
130
hydrogen-free) polymers and corresponding com-
pounding and processing techniques, materials with 110
rubber-elastic properties can be manufactured, which
90
closely resemble PTFE in their media resistance and
thermal resistance. This very expensive material is used 70
10 100 1000 10000
anywhere where extreme safety standards apply and Time in use h
a high maintenance and repair effort justify the price
for these diaphragms. Preferred areas are the chemical Fig. 16 Permissible temperature-time limit for some elastomers
industry, the crude oil production and processing indus- under the influence of warm air)
try, equipment and power plant construction and in the
aviation and aerospace technology. FVMQ – Fluoro silicone rubber
Thermal operating conditions from-15 °C to +230 °C. Is used for special requirements with regard to fuel re-
sistance under cold temperatures.
FKM – Fluoro elastomer rubber Temperature range approx. -60 °C to +175 °C.
Is characterised by high thermal and chemical resist-
ance as well as low values for gas emission and gas HNBR – Hydrogenated acrylonitrile-butadiene
permeability at room temperature. FKM is the preferred rubber
material for diaphragms in vacuum technology as well Has a higher resistance to heat and physical strength
as in usage with gases and fluids with a high aromatic with less abrasion than NBR. The chemical resistance is
level ("super fuels"). Special fluoro elastomers are nec- in many cases identical to NBR.
essary for use with water vapour (on enquiry). It is better suited against mineral oils (e.g. pentosine
Cold behaviour
CHF 11S, dexron III).
An application case would be, for example, an accu-
4
mulator diaphragm for hydraulic oil. HNBR also has an
10 4
5
even higher dynamic load resistance than NBR, this is
used for applications as a pump diaphragm.
Operating conditions from 30 °C to +150 °C.
103 3
5
IR – Butyl rubber
mm2
dN
1
5 This is the standard material for all diaphragms pres-
surised with compressed air and mineral oils. Types with
D
1 0
a higher acrylonitrile content are used if sealing against
-120 -80 -40 0 40 80 120 160 natural gas, propane and all oils based on mineral oil
°Celsius
are desired. For better resistance against swelling and
Fig. 15 Behaviour when cold gas proofness, worse cold temperature characteristics
must be accepted as a trade-off.
88 ≥7,0 0,12 medium Insert parts are considered to be those of any type
Polyamide fabric of material that is vulcanised into the diaphragm. The
spectrum ranges from simple metals through to modern
22 ≥22,0 0,36 limited
synthetics. These "inserts" handle various functions.
29 ≥29,0 0,70 limited For instance, they convey linear shaft force to the dia-
31 ≥110,0 0,60 limited phragm or stiffen it at the desired location.
32 ≥60,0 0,38 medium
Adhesive agents are used in order that these parts ad-
57 ≥33,0 0,32 good
here properly to the product. Our chemical engineering
143 ≥56,0 0,40 limited can offer the right solution to almost all conventional
Aramide fabric (Nomex) rubber-metal combinations.
Symbols used
Housing diameter Dg mm
Piston diameter Dk mm
Mean diameter Dm mm
Effective diameter Dw mm
Elongation ε –
Tension σ N/mm2
Temperature T °C
Products
Diaphragms
Diaphragms 743
Long-Stroke Rolling Diaphragms BFA 744
Rubberised Fabric 747
Diaphragms for Pumps and Compressors 749
Diaphragms for Accumulators and Bladders 750
Diaphragms for Industrial Valves 751
Diaphragms
Application
Material
Long-stroke rolling diaphragms with fabric layer, the and push piston into the cylinder. In this way the roll-
fabric must be on the non-pressurised side. The dia- ing convolution is formed. The piston must be secured
phragm is inverted before fitting. Should the rolling against twisting after fitting to avoid the formation of a
convolution formed in this way arch upwards when skewed convolution. A plain washer is sufficient as the
performing this action, the use of a mounting sleeve is spring support. Stroke limiting is always to be provided.
necessary. The rolling area for the diaphragm must to be finely
Do not use a screwdriver! machined and polished. The transition radii on the
Another possible fitting method: fit inverted rolling clamping flange, piston base and cover plate are to be
diaphragm to the piston, place bead in the groove smooth and free from scoring.
Fitting sleeve
Installation dimensions
Diaphragm dimensions
on the piston Lk 0,5 (H+Sa) 0,5 (H+Sa) 0,5 (H+Sa) 0,5 (H+Sa)
on the cylinder Lc 0,5 (H+Sb) 0,5 (H+Sb) 0,5 (H+Sb) 0,5 (H+Sb)
Diaphragm stroke
in one direction
Sa H–8 H–14 H–20 H–20
max.
in opposite
Sb H–8 H–14 H–20 H–20
direction max.
Fastening plate
Rubberised Fabric
Material
Product advantages
Fitting & installation
Flat diaphragms can be punched from these rubberised
fabrics without problems. The manufacture of moulded A prerequisite for clean sealing in the clamping area is
diaphragms is performed by embossing at raised adequate compression (10% of sheet thickness) as well
temperatures, here certain restrictions in relation to the as a score-free surface on the metal or plastic parts.
diaphragm height that can be attained must be taken
into account depending on the fabric quality and mate-
rial thickness.
Application
Code Elas- Fabric Nomi- Max. Thick- Toler- Colour Operating Media
tomer nal tensile ness ance temperature
width force [mm] min/max
[mm] [N/mm] [°C]
MT 471/
NBR PA 1,40 11 0,30 ±0,03 Blue –25 … +90 B
505412
Fuels, heating and fuel
MT 479/ gases, mineral oils,
NBR PA 1,40 11 0,17 ±0,03 Blue –25 … +90 B
505414 greases, inorganic
acids and bases, flame
MT 481/
NBR PES 1,50 50 0,90 ±0,07 Blue –25 … +90 resistant hydraulic B
505415
fluids (HFA, B, C),
MT 486/ oil-bearing com-
NBR ZW 1,50 15 0,38 ±0,05 Red –20 … +90 B
505416 pressed air, water to
80 °C
MT 496/
NBR PA 1,50 50 1,10 ±0,15 Red –30 … +90 B
147030
MT 488/ Red/
NBR PA 1,50 50 1,10 ±0,15 –20 … +90 Diesel fuels, mineral B
49042567 Green c)
oils,
MT 489/ Red/ oil-bearing com-
NBR PA 1,50 40 0,68 ±0,07 –20 … +90 B
49042568 Green c) pressed air, heating
oils, water up to
MT 490/
NBR PA 1,50 24 0,40 ±0,05 Green –20 … +90 80 °C B
505417
MT 475/
CR PES 1,50 25 0,45 ±0,05 Black –30 … +90 Oil-bearing air, water B
505413
(ozone and UV
MT 510/ resistant)
CR PA 1,50 50 1,10 ±0,15 Black –30 … +90 B
49046470
MT 491 ECO PA 1,40 11 0,32 ±0,05 Black –35 … +130 Fuels, oils, greases, air B
MT 504 ECO PA 1,50 30 1,00 ±0,10 Black –35 … +130 (max. 130 °C) B
Application
Material
Product advantages
Application
Material
Operating conditions
Accumulator Bladders
All known hydraulic fluids and
Media
gases (nitrogen)
Product description
Product advantages
Material
NBR, HNBR, EPDM, CR, ECO, AU, VMQ, FKM, FFKM, special
Elastomer
silicon-based materials and TPU
Operating conditions