The present invention relates to a pressure regulated flow valve including a gas piston which compensates for the decreasing internal pressure inside a pressurized product dispensing container to ensure sufficient product is ejected through the valve even as the pressure in the dispensing container falls. Where the internal pressure within the pressurized product dispensing container decreases below a certain threshold pressure, the valve via the gas piston provides for an increase in the flow of the product being dispensed from the pressurized container through the pressure regulated flow valve so as to maintain a relatively consistent flow rate of product.
In the aerosol container industry fluorocarbons or hydrocarbons are typically utilized as the propellant in a pressurized aerosol container because these compounds are generally soluble with the product to be dispensed. These compounds remain in such a soluble state whatever amount of the product is expelled from the can thereby maintaining essentially a constant pressure within the container. In this way a constant pressure is generally available to dispense the product when the valve is actuated by a user, no matter how depleted the product in the container has become. However, due to the potential environmental harm which can be caused by the fluorocarbons and hydrocarbons to the environment, there has been increasing pressure in the market to replace the fluorocarbons and hydrocarbons with more benign propellants.
Various attempts have been made to utilize compressed gases as the propellant for dispensing the product contents of a pressurized container instead of fluorocarbons, compressed air, CO2 or N2 for example. However, one major drawback associated with utilizing a compressed gas is that these gases are generally not soluble in the product. Thus, as the product contents are gradually dispensed from the pressurized container over time, the internal pressure within the pressurized container also gradually decreases. The reduction in the internal pressure of the pressurized container significantly reduces the flow rate of the remaining product contents from the pressurized container. The pressure may even drop so low as to not be able to expel any further product from the container.
For example, with such compressed gases where a container is pressurized with an initial pressure of 100 psi of pressurized gas, such as air, the product will dispense initially at the intended flow rate from the pressurized container. However, as the product contents are gradually dispensed over time, the volume in the container for the compressed gas expands and the internal pressure of the container for forcing out the product gradually decreases to, for example, only 20 psi. As a result of this reduction in dispensing pressure, the flow rate of the remaining product also decreases and the product then has a tendency to trickle out of the valve as such product is dispensed. The significant pressure drop and decrease in product flow rate is generally unacceptable and has hindered the use of compressed gases in conventional valves and pressurized containers.
Wherefore, it is an object of the present invention to overcome the above mentioned shortcomings and drawbacks associated with the prior art dispensing valves.
An object of the present invention is to provide a valve which has a primary flow path through the valve and has an internal movable member which is regulated by the internal pressure of the pressurized container as well as the internal pressure of a gas piston so that as the internal pressure of the pressurized container falls below a threshold value, the gas piston biases the movable member in a manner which controls the expansion of the product flow path so that a desired sustained volumetric flow rate of product can continue to be emitted from the pressurized container despite the loss of internal pressure in the container.
A further object of the present invention is to change the flow path characteristics of the pressure regulated flow valve once the internal pressure inside the pressurized container falls below a predetermined threshold pressure of between about 40 to 65 psi for example, the flow path characteristics of the regulated flow valve are automatically modified so that the cross-sectional area of the flow path is modified, and an increased volume of the product is then able to be dispensed via a larger flow path area.
Another object of the present invention is to utilize a relatively environmentally harmless compressed gas, such as compressed air, CO2 or N2 as a propellant for dispensing the product contents, and thus eliminate the use of fluorocarbons, hydrocarbons and other harmful compounds as the propellant for the pressurized container.
A still further object of the present invention is to provide a pressure regulated flow valve in which the associated manufacturing and assembly costs are minimized while still providing a reliable pressure regulated flow valve which can maintain a relatively consistent flow rate both at a high internal pressure and at low internal pressure.
Yet another object of the present invention is to provide a pressure regulated flow valve in which the overall size and profile of the piston member, the internal pressure of the pressurized container and the pressure of the gas piston all interact with one another to dictate the threshold pressure at which the regulated flow valve transitions from high pressure condition to low pressure condition.
Another object of the present invention is to provide a variably sized orifice as a primary flow path between the valve housing and the movable member which can be variably sized by relative movement of the moveable member according to the relative pressure difference between the gas piston cylinder and the container.
The present invention also relates to a pressure regulated flow valve for dispensing product from a pressurized container, the pressure regulated flow valve comprising a valve housing having an upper chamber accommodating a valve stem and a lower chamber accommodating a gas piston cylinder comprising a movable piston, and a flow controller connected to the movable piston, a first pressure inside of the gas piston cylinder and a second pressure inside of the container, a passageway for dispensing variable amounts of product through the valve housing; and wherein the passageway has a variable sized opening defined by the flow controller according to a relative difference between the first and the second pressures.
The present invention also relates to a method of regulating a flow valve for dispensing product from a pressurized container, the method comprising the steps of defining a valve housing having an upper chamber accommodating a valve stem and a lower chamber accommodating a gas piston cylinder comprising, a movable piston, and a flow controller connected to the movable piston, providing a first pressure inside of the gas piston cylinder and a second pressure inside of the container, forming a passageway for dispensing variable amounts of product through the valve housing, and allowing the passageway to have a variable space created by the flow controller and determined by the second pressure inside of the container.
The invention will now be described, by way of example, with reference to the accompanying drawings in which:
With reference to
Turning specifically to the valve 102, a valve stem 103 is supported in the housing 104 and extends through an opening in the mounting cup 106 to provide the necessary mechanical trigger and product passageway 105, for example a tilt valve stem or vertically actuated valve stem, which permits a user to eject the pressurized product from the container 108. The valve stem 103 has a top and bottom portion between which the valve passageway 105 extends and through which the product passes from the container 108 so as to be finally ejected from the top portion of the valve stem 103. A stem entry orifice 107 is generally formed in a radial relationship to the valve passage 105 in the sidewall of the valve stem 103. The orifice 107 communicates between an internal passage or cavity 110 of the valve 102 and the valve passage 105 to permit product flow into the valve passage 105 upon pressing or tilting of the valve stem 103.
A gasket 109 seals the orifice closed in an unactuated position as shown in
The valve housing 104 defines the internal cavity 110 which in turn defines a flow path F for the outgoing pressurized product as it travels from the interior of the container 108 through the housing 104 to the valve stem 103. The valve housing 104 is open at opposed upper and lower ends, with the upper end supporting the gasket 109 and stem 103 at one end thereof as described above, and as described in further detail below a pressurized product inlet at the other end including a gas piston cylinder. The internal cavity 110 is substantially cylindrical in shape and generally comprises an upper chamber portion 120 and a lower chamber portion 118. What essentially separates the upper and lower chamber portions 118 and 120 is that the lower chamber portion 118 includes the gas piston cylinder device 122 which essentially functions as a variable gateway in the valve 102 so as to ensure a consistent dispensing of product from the valve even as the internal pressure P of the container 108 drops, as will be described in detail below.
As shown, the lower chamber portion 118 in this first embodiment in
In the embodiment of
The control rod 134 is provided with a taper 138 along its axial length extending from a larger diameter attached to the base 136 to a smaller diameter end spaced therefrom and located within the flow path F. It is to be appreciated that this taper along the length of the control rod 134 could be consistent so that the change of area of the plate orifice 124 is essentially linear relative to the length of the control rod 134. Alternatively the taper could be variable, for example concave or convex along the length of the control rod 134, so that the change of area of the plate orifice 124 relative to the control rod 134 was non-linear
The plate orifice 124 is provided with a certain diameter in relation to the control rod 134. In general, the plate orifice 124 is provided with a slightly larger diameter than the largest diameter of the control rod 134 so that there is always a minimal area or space between the outer diameter of the control rod 134 and the inner surface of the flow path F. Pressurized product is thus permitted to flow through this area or space defined by the plate orifice 124 and the immediately adjacent axial section of the control rod 134. It is to be appreciated that the taper of the control rod 134 as discussed above, determines the flow path cross-sectional area depending on where the tapered control rod 134 is axially aligned with respect to the plate orifice 124 and in effect creates a variable size opening into the flow path F. It is to be appreciated that the taper on the control rod 134 may be a linear taper, or in the alternative it may also be a convex or concave taper as shown by way of example in
The piston cylinder 126 as seen in
As the pressurized product is ejected from the container 108, the initial pressure Pi in the container 108 gradually lowers to Pi−x. At a predetermined point, depending on the initial charge pressure N of the gas piston cylinder 126, Pi−x attains a pressure permitting the gas piston pressure N to gradually move the piston 132 from the substantially closed position outwards. When the piston 132 is pushed out of the cylinder 126, the entire base 136 moves as well causing the control rod 134 to move outward relative to the plate orifice 124. When the control rod 134 moves, the flow path F increases gradually in size according to the taper 138 and allows for a greater volume of product to flow from the container to the internal cavity 110 and eventually out the valve passage 105. The increase in the volume of the flow path as the pressure drops helps ensure a relatively constant flow of product is maintained from the device and compensates for the decrease in the internal pressure P.
As the internal pressure P continues to decrease past the Pi−x threshold, the piston 132 is pushed farther and farther outward by the decreasing gas piston pressure N. This will eventually result in either the piston 132 reaching a maximum outward position and thereby defining a least restrictive position of the control rod 134; or it will result in the internal pressure P reaching a state of equilibrium with the gas piston pressure N. Either way, the piston 132, and therefore the control rod 134, alters the size of the inlet plate orifice 124 between the substantially closed position as shown in
In a further embodiment of the present invention shown in
In a yet further embodiment of the present invention, the flow control device is no longer a rod or needle, but is instead a cylindrical cap 322 directly attached to the movable piston 332 as seen in
This embodiment operates in a similar fashion as the previous embodiments to increase the area of the inlet orifice 324 as the container pressure P decreases. Instead of a tapered rod however, as the piston 332 moves outward due to a decrease in the pressure P inside of the container, the cylindrical cap 322 moves outward as well pulling the free edge 328 farther away from the shoulder 330 creating a larger opening and more area for the product to flow through into the valve housing and up the passage F to the upper chamber 320 and eventually out of the valve passage 305.
In a similar embodiment of the present invention, the cylindrical wall 438 of the cap 422 directly attached to the movable piston 432 is narrowed and extends along the housing 404 as seen in
Since certain changes may be made in the above regulated flow valve, without departing from the spirit and scope of the invention herein involved, it is intended that all of the subject matter of the above description or shown in the accompanying drawings shall be interpreted merely as examples illustrating the inventive concept herein and shall not be construed as limiting the invention.
This application claims the benefit of International Application No. PCT/US2010/061873 filed Dec. 22, 2010, entitled Pressure Regulated Flow Valve with Gas-Piston and published as WO2011/079219 on Jun. 30, 2011 and of U.S. Provisional Application No. 61/289,505 filed Dec. 23, 2009 and entitled Pressure Regulated Flow Valve with Gas-Piston, which are each hereby incorporated by reference in their entirety.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US2010/061873 | 12/22/2010 | WO | 00 | 5/18/2012 |
Publishing Document | Publishing Date | Country | Kind |
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WO2011/079219 | 6/30/2011 | WO | A |
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7721919 | Vanblaere et al. | May 2010 | B2 |
Number | Date | Country |
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645070 | Sep 1984 | CH |
8018112 | Apr 1996 | JP |
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8108111 | Apr 1996 | JP |
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Entry |
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International Search Report dated Jun. 30, 2011 received in International Application PCT/US2010/061873, 5 pgs. |
Number | Date | Country | |
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20120228336 A1 | Sep 2012 | US |
Number | Date | Country | |
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61289505 | Dec 2009 | US |