The invention relates to a mechanical valve assembly used to control the flow of a gas or liquid to provide at least one of a low flow control features and check valve control features.
In physics and engineering, fluid dynamics is a subdiscipline of fluid mechanics that describes the flow of fluids (e.g. liquids, gases). Fluid dynamics has several subdisciplines, including aerodynamics and hydrodynamics. Fluid dynamics has a wide range of applications, including determining the mass flow rate of petroleum/water through pipelines. Such applications often require the use of a control valve.
A flow control valve regulates the flow or pressure of a fluid. Control valves normally respond to signals generated by independent devices such as flow meters or temperature gauges. Prior art control valves are normally fitted with actuators and positioners. Such valves are often referred to as automatic control valves as the hydraulic actuators respond to changes of pressure or flow to open/close the valve. Automatic control valves generally do not require an external power source, meaning that the fluid pressure is enough to open and close them.
Automatic control valves include check valves. A check valve is a type of valve which allows a fluid liquid or gas to flow in a forward direction only. In reverse flow conditions, the valve closes to prevent flow. Prior art inline check valves generally have two ports, an inlet and an outlet, with self-contained mechanical controls. The actuation of the valve is controlled by forward and reverse opposing forces. Forward forces may include upstream pressure, seat opposing forces, and flow forces when flow is present. Opposing forces may include downstream pressure, inertia forces, and spring forces when a spring is present. When upstream forces overcome downstream forces, the valve opens, and flow passes through the valve. Thus, check valves work automatically, and most are not directly controlled by a person or any external control.
An important concept in check valves is the “cracking pressure”, or the point of minimum upstream pressure at which the valve will operate. Typically, the check valve is designed for and can therefore be specified for a specific cracking pressure. For prior art devices, at higher flow rates, the valve is in the fully open position and operates at predictable pressure drops and flow streams can be accurately predicted. At low flow conditions, however, the valve is only partially open, where the resulting flow rate is based on the percent of travel of the component that “opens” to allow flow.
Low flow conditions can be particularly troublesome for applications being metered by a flow meter that have inter moving parts for measurement elements that measure fluid flow. As the fluid passes through such meter, the fluid flow activates the meter's measurement elements causing movement (e.g. spinning wheel or associating a plate, etc.). Very Low Fluid flow rates can often have inefficient inertia for triggering the flow registering elements in devices such as flow meters. Such low flow simply passes through the meter without being metered resulting in revenue loss to the entity metering the fluid consumption (typically a fluid supplier such as a utility company).
What is needed is a valve technology that prevents undesired low flow rates. Restated, the technology would prevent flow out of the valve at initial travel points (i.e. travel of the component that “opens”) where the inertia of the fluid is insufficient to move a meters' measurement elements. Once a specific predefined travel set point is reached, the device should allow the flow to “jump up” to a range set by the associated travel.
The technology disclosed and claimed in this document teaches such a device.
Some of the objects and advantages of the invention will now be set forth in the following description, while other objects and advantages of the invention may be obvious from the description or may be learned through practice of the invention.
One general object of the present invention is to provide a fluid control valve that prevents a predefined low flow rate while allowing a desired flow rate.
Another object of the present invention is to provide a flow control valve that prevents flow until a predefined flow rate is achieved downstream of the flow control valve so that the flow “jumps” from no flow to a higher flow rate that can be more accurately measured by a metering element.
Yet another object of the present invention is to provide a mechanical valve assembly used in the control of a fluid (e.g. gas, liquid, etc.) to provide a check valve control feature and flow range control feature. When unwanted low flows are present, the valve remains closed and jumps open only at the higher wanted rates. The valve then closes when downstream flow stops. Flow is delivered to the flow meter in larger segregated bursts, rather than steady low flows at unwanted flow rates (i.e. low flow rates that cannot be measured by a meter).
Additional objects and advantages of the present invention are set forth in the detailed description herein or will be apparent to those skilled in the art upon reviewing the detailed description. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referenced, and discussed steps, or features hereof may be practiced in various uses and embodiments of this invention without departing from the spirit and scope thereof, by virtue of the present reference thereto. Such variations may include, but are not limited to, substitution of equivalent steps, referenced or discussed, and the functional, operational, or positional reversal of various features, steps, parts, or the like. Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of this invention may include various combinations or configurations of presently disclosed features or elements, or their equivalents including combinations of features or parts or configurations thereof not expressly shown in the figures or stated in the detailed description.
Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the remainder of the specification.
A full and enabling description of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference now will be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present invention are disclosed in or may be determined from the following detailed description. Repeat use of reference characters is intended to represent same or analogous features, elements or steps. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present invention.
For the purposes of this document two or more items are “mechanically associated” by bringing them together or into relationship with each other in any number of ways including a direct or indirect physical “releasable connections” snaps, screws, Velcro®, bolts, etc.—generally connections designed to be easily and frequently released and reconnected, “hard-connections” welds, glue, rivets, macular bonds, generally connections that one does not anticipate disconnecting very often if at all and that are “broken” to separate, and/or “moveable connections” rotating, pivoting, oscillating, etc.
As used herein, unless stated otherwise, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.
As used herein, the terms “upstream” and “downstream” refer to the relative location of components in a fluid pathway. For example, component A is upstream of component B if a fluid flows from component A to component B. Conversely, component B is downstream of component A if component B receives a fluid flow from component A.
The actuation of the valve is controlled by forward and reverse opposing forces. Forward forces may include upstream pressure, seat opposing forces, and flow forces when flow is present. Opposing forces may include downstream pressure, inertia forces, and spring forces when a spring is present.
As used herein, the term “axial” refers to a direction of flow through an object; the term “radial” refers to a direction extending away from the center of an object or normal to the “axial” direction, and the term “circumferential” refers to a direction extending around the circumference or perimeter of an object.
For the purposes of this document, unless otherwise stated, the phrase “at least one of A, B, and C” means there is at least one of A, or at least one of B, or at least one of C or any combination thereof not one of A, and one of B, and one of C.
This document includes headers that are used for place markers only. Such headers are not meant to affect the construction of this document, do not in any way related to the meaning of this document nor should such headers be used for such purposes.
While the examples herein may be directed to a water delivery system comprising a meter measuring water consumption, the disclose technology may be used to control the flow of any type of fluid delivery system.
As noted previously, a check valve is a type of valve designed to allow a fluid (liquid or gas) to flow in a forward direction only. In reverse flow conditions, the valve closes to prevent flow. Inline prior art mechanical check valves are generally self-contained and have an inlet and an outlet port where the actuation of the valve is controlled by forward and reverse opposing forces. Forward forces include upstream pressure, seat opposing forces, and flow forces when flow is present. Opposing forces include downstream pressure, inertia forces, and spring forces when a spring is present. When upstream forces overcome downstream forces, the valve opens, and fluid flows through the valve. For example, a utility may supply water to a home via a pipeline comprising a meter to measure consumption. Such utility is “upstream” from the home as the utility supplies fluid to the home. A check valve may also be placed into the pipeline so that fluid can only flow from the utility pipeline to the home.
Further, most flow meters depend on the inertial energy of the fluid flowing through the meter to activate the meter's flow measurement elements. During some low flow conditions such fluid does not have enough inertial energy to start the flow measurement elements, and thus, such flow is not measured. Embodiments of the present invention may be referred to herein as a “jump valve” and is preferably configured to prevent undesired low flow rates for a fluid and may further provide a check valve feature.
Referring now to
As depicted in
As best seen in
Preferably all the fluid flowing through the flow control apparatus 10 flows through the plurality of holes defined by the inlet plate 20 and outlet plate 22. Ideally, the total area of such plurality of holes (for each plate) is greater than the inner diameter of the supply pipe to be associated with the inlet body 14 and/or the outlet body 16.
A core element 24 is now considered in more detail. One embodiment of a core element is poppet element 24 which defines a circular perimeter defining a poppet diameter and wherein the poppet element 24 further defines an upstream face 42 and (for some embodiments) an opposing downstream resilient element receiver 44. At least a portion of the upstream face defines a poppet face seal zone 46 and at least a portion of the perimeter defines a circumferential poppet perimeter flow zone 48.
As best seen in
For the purposes of this invention, the delta force is defined as the inlet side forces minus the outlet side forces. When the delta forces are positive, the poppet element 24 moves in the downstream direction until it reaches a fully open limit. When the delta forces are negative the poppet element 24 moves in the upstream direction until it reaches a fully closed limit.
As best seen in
For one embodiment, the sealing member 28 is flexible and resilient to allow small backflow amounts in response to sudden pressure changes such as pressure changes caused by water hammer. Such a configuration helps to limit damage to components in the fluid deliver system and associated meter that would otherwise be caused by water hammer. For one alternative embodiment, the sealing member 28 is more ridged and prevents backflow providing a traditional backflow check valve feature.
Similarly, as best seen in
Similar to the sealing member 28 and damping element 30, as best seen in
Based on the above disclosure, one of ordinary skill in the art will appreciate that when the poppet face seal zone 46 is engaging the sealing engagement zone 60 the fluid delta forces have reached a predefined first value (basically they cancel and there is no delta). In this state the flow control apparatus 10 is in the full closed position an there should be no fluid flow through the hollow body 12. When the fluid delta forces increase to a second predefined value (as a result of a very low flow downstream the outlet body) the poppet element 24 moves slightly in the downstream direction and small amount of fluid flows through the damping zone but not through the inlet body 14. Eventually the pressure delta will reach a third predefined value and the poppet face seal zone 46 disengages with said sealing element zone 60 allowing a pulse of fluid flow through the meter until the delta forces equalize again and the valve closes preventing flow out of the outlet body. This is an example of an undesired low flow condition being converted to a higher pulse flow. The poppet element 24 will move even further in the downstream direction so that the damping flow zone disengages with said poppet perimeter flow zone 48 when the fluid delta forces exceed a predefined third value thereby allowing fluid flow through said hollow cylindrical body.
Stated differently, suppose a water utility supplies water to a customer through a water meter associated with the disclosed flow control apparatus 10. Suppose the customer has a shower that leaks a drip at a time resulting in a low flow rate that cannot be measured by the water meter. As the pressure on the output side slowly drops as water is drained from damping flow area due to the drip leak, the poppet element moves slightly in the downstream direction. Eventually the low flow will cause the pressure on the output side of the flow control apparatus to drop so much that the poppet element will disengage from the damping element allowing fluid flow out the flow control apparatus to “jump” to a predefined value that can be measured by the meter. Such “jump” flow will replenish the fluid lost due to the leak and input and output pressure will equalize and the valve will close, and the process will start all over again. If the customer should turn on the shower, for example, the resulting high flow rate will cause the flow control apparatus to fully open and stay open until the shower is turned off.
Referring now to
Referring now to
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.
This application claims priority to U.S. Provisional application 62/673,224 filed on 18 May 2018 the contents of which are hereby incorporated by this reference for all that it discloses for all purposes.
Number | Date | Country | |
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62673224 | May 2018 | US |