Patent Application
20070272313
The following brief description of the figures, and the related figures themselves, exemplifies a particular preferred embodiment of the invention constituting the best mode presently contemplated. As will be understood, other embodiments of the invention as well as changes and variations in the particular structure shown in these figures are no doubt possible, and may very well suggest themselves to those skilled in the art after studying this disclosure and these figures.
For purposes of description herein, the terms “upper,” “lower,” “vertical,” and derivatives thereof shall relate to the invention as orientated in
The reference number 10 (
In the illustrated embodiment, the two-stage pressure regulator has an upper body 24 (sometimes called the “bonnet”), a middle body 26 and a lower body 28. The middle body 26 and the lower body 28 are preferably made by die casting. It is contemplated that the upper body 24 can be made by die casting or by stamping, among other methods. The middle body 26 is connected to the upper body 24 by a plurality of rivets 30. Alternatively, the middle body 26 could be connected to the upper body 24 by mechanically deforming, or crimping, an upstanding flange on the outside of an upper portion of the middle body 26 over an outer flange of the upper body 24. The crimp could also be reversed with a downward flange on the outside of the lower end of the upper body 24 and an outer flange on the middle body 26. Alternatively, the upper body 24 can have an outer flange at a lower end, which connects to an upper portion 18 of the middle body 26 by a plurality of threaded fasteners. As illustrated in
In the illustrated example, the first regulator portion 10a of the two-stage gas pressure regulator 10 includes a first regulating assembly 34 for controlling the flow of fluid from the inlet 20 to the second regulator portion 10b. The first regulating assembly 34 is located within a first regulator cavity 36 defined by the middle body 26 and the lower body 28. The first regulator cavity 36 includes a lower threaded aperture 38 that ends at the inlet 20, a constriction 40 and an upper cavity area 42. The constriction 40 is located between the lower threaded aperture 38 and the upper cavity area 42. The lower threaded aperture 38 and the constriction 40 are located in the lower body 28. The upper cavity area 42 includes a first portion 43 in the lower body 28 above the constriction 40 and a second portion 45 in a lower portion of the middle body 26 that is substantially co-extensive with the first portion 43 of the upper cavity area 42 in the lower body 28. The lower body 28 also includes a passage hole 44 that allows gas to pass from the first portion 43 of the upper cavity area 42 in the lower body 28 to the second regulator portion 10b.
The illustrated first regulating assembly 34 includes a first diaphragm 46, a first spring 50, a first plate 52, a first post 54, a first stem 56 and a first regulating disc 58. The first diaphragm 46 is clamped between the lower body 28 and the middle body 26, thereby defining the first portion 43 and the second portion 45 of the upper cavity area 42. The first plate 52 is located on top of the first diaphragm 46. The first spring 50 abuts against a top of the second portion 45 of the upper cavity area 42 and the first plate 52. The first diaphragm 46 is biased downwardly by the first spring 50, which acts against the top of the first diaphragm 46 (via the first plate 52). The first diaphragm 46 is connected to the first post 54, which extends through the first diaphragm 46 and is connected to the first stem 56. The first post 54 moves the first stem 56 vertically to move the first stem 56 vertically in a reciprocal motion through the constriction 40. The first regulating disc 58 is connected to a lower end of the first stem 56 adjacent the constriction 40. The first regulating disc 58 is preferably made of rubber, although other compositions are contemplated. The first regulating disc 58 controls the amount of gas allowed to flow from the inlet 20 through the constriction 40 and to the passage hole 44 by selectively covering the constriction 40.
During typical use of the illustrated pressure regulator 10, fluid flows through the first regulator portion 10a from the source of fuel, though the inlet 20 (typically via the probe), through the first regulator cavity 36 of the first regulator portion 10a and to the passage hole 44. However, when pressure in the first portion 43 of the upper cavity area 42 of the first regulator cavity 36 raises above a certain level, the gas in the first portion 43 of the upper cavity area 42 of the first regulator cavity 36 will press against an underside 60 of the first diaphragm 46 and move the first diaphragm 46 upward against the bias of the first spring 50. Preferably, the second portion 45 of the upper cavity area 42 includes a hole 51 to the outside of the pressure regulator 10, such that the air in the second portion 45 of the upper cavity area 42 is at atmospheric pressure. In this situation, the upward movement of the first diaphragm 46 will cause the first spring 50 to compress, thereby forcing the first post 54 upwards. Upward movement of the first post 54 will force the first stem 56 to also move upward, thereby forcing the first regulating disc 58 to cover the constriction 40. Accordingly, when the pressure in the first regulator cavity 36 below the first diaphragm 46 is above a certain level, the first regulating disc 58 will cover the constriction 40 and prevent fluid flow through the constriction 40 of the first pressure regulator portion 10a.
In the illustrated example, the second regulator portion 10b of two-stage gas pressure regulator 10 includes a second regulating assembly 62 for controlling the flow of fluid from the first regulator portion 10a to the outlet 22. The second regulating assembly 62 is located within a second regulator cavity 64 defined by the upper body 24, the middle body 26 and the lower body 28. The second regulator cavity 64 includes an upper first area 66 and a lower second area 68. The upper first area 66 includes a first area upper portion 69 defined by the upper body 24 and a first area lower portion 70 in the top of the middle body 26. The first area upper portion 69 and the first area lower portion 70 are substantially co-extensive. The lower second area 68 is located below and to the side of the upper first area 66. The lower second area 68 includes a lower cavity 72 substantially parallel to and adjacent the lower threaded aperture 38 of the first regulator cavity 36, a middle opening 74 above the lower cavity 72, an upper orifice 76 above the middle opening 74, and a stem tube 78 above the upper orifice 76. The lower cavity 72, the middle opening 74, the upper orifice 76 and the stem tube 78 are all preferably substantially tubular and have a common axis. The lower cavity 72, the middle opening 74 and the upper orifice 76 are located in the lower body 28 and the stem tube 78 is located in the middle body 26. A first shelf 82 defines a transition between the lower cavity 72 and the middle opening 74. Furthermore, a second shelf 84 defines a transition between the middle opening 74 and the upper orifice 76. The passage hole 44 opens to the middle opening 74. Furthermore, an outlet tube 80 extends from the upper orifice 76 to the outlet 22 (see
The illustrated second regulator cavity 64 includes a plurality of elements to define a fluid path through the second regulator cavity 64 and to enclose the second regulator cavity 64. The lower cavity 72 of the lower second area 68 of the second regulator cavity 64 includes a threaded bottom 200 having a threaded first plug 202 inserted therein to enclose the second regulator cavity 64. A second plug 204 is located above the threaded first plug 202 in the lower cavity 72, with a top of the second plug 204 abutting the first shelf 82. A top of the second plug 204 also defines a bottom of the middle opening 74. An orifice constriction member 206 rests on the second shelf 84 in the upper orifice 76. The orifice constriction member 206 includes a center aperture 208 having a lower wide portion 210, a middle portion 212 and an upper narrow portion 214. An O-ring 216 is located in the lower wide portion 210 and is compressed between the second shelf 84 and the orifice constriction member 206. A spacer 218 sits on the orifice constriction member 206 between a bottom of the middle body 26 and the orifice constriction member 206. As illustrated in
The illustrated second regulating assembly 62 includes a second diaphragm 86, a second spring 88, a second plate 90, a second post 92, a third spring 23 between the second diaphragm 86 and the second post 92, a pivot actuator 94, a second stem 96 and a second regulating disc 98. The second diaphragm 86 is clamped between the upper body 24 and the middle body 26. The second diaphragm 86 separates the upper first area 66 into the first area upper portion 69 above the second diaphragm 86 and the first area lower portion 70 below the second diaphragm 86. The second plate 90 is located on top of the second diaphragm 86. The second spring 88 abuts against a top of the upper first area 66 and the second plate 90. The second diaphragm 86 is biased downwardly by the second spring 88, which acts against the top of the second diaphragm 86 (via the second plate 90). The second diaphragm 86 is connected to the second post 92 via the third spring 23, which extends through the second diaphragm 86 and is pivotally connected to the pivot actuator 94. The pivot actuator 94 extends through the middle body 26 and is pivotally connected to the middle body 26 by a pin 100. The pivot actuator 94 includes a lever head 102 connected to a middle of the second stem 96. The second post 92 pivots the pivot actuator 94 about the pin 100 and moves the second stem 96 vertically within the stem tube 78 to move the second stem 96 vertically in a reciprocal motion. The second regulating disc 98 is connected to a lower end of the second stem 96 adjacent a top of the orifice constriction member 206. The second regulating disc 98 controls the amount of gas allowed to flow from the passage hole 44 to the outlet 22 by selectively covering the orifice constriction member 206 to prevent flow of the gas through the center aperture 208 of the orifice constriction member 206.
During typical use of the illustrated pressure regulator 10, fluid flows through the second regulator portion 10b from the from the passage hole 44, through the lower second area 68 of the second regulator cavity 64 of the second regulator portion 10b and to the outlet 22. However, when pressure in the second regulator cavity 64 raises above a certain level, the gas in the second regulator cavity 64 will press against an underside 120 of the second diaphragm 86 and move the second diaphragm 86 upward against the bias of the second spring 88. It is noted that the fluid pressure is communicated from the lower second area 68 to the first area lower portion 70 of the upper first area 66 via the channel 104. In this situation, the upward movement of the second diaphragm 86 will cause the second spring 88 to compress thereby forcing the second post 92 upwards. Upward movement of the second post 92 will force the pivot actuator 94 to pivot about the pin 100. Therefore, the lever head 102 will force the second stem 96 to move downward, thereby forcing the second regulating disc 98 to cover the center aperture 208 of the orifice constriction member 206. Accordingly, when the pressure in the first area lower portion 70 of the second regulator cavity 64 is above a certain level, the second regulating disc 98 will cover the center aperture 208 of the orifice constriction member 206 and prevent fluid flow through the orifice constriction member 206, thereby preventing fluid flow through the second regulator portion 10b. Preferably, the first area upper portion 69 of the upper first area 66 of the second regulator cavity 64 includes a hole 101 to the outside of the pressure regulator 10, such that the air in the first area upper portion 69 is at atmospheric pressure.
The pressure regulator of the present invention provides a simplified and very compact design. The use of only one upper body 24 (or bonnet) instead of a pair of bonnets reduces the overall cost of the regulator 10 as the bonnets can be very expensive to produce. Furthermore, locating the orifice constriction member 206 adjacent the outlet tube 80 reduces disruption of the gas flow through the regulator 10, thereby greatly reducing instability or humming (the disruption previously occurred when gas that must flow through the second regulator cavity 64 is interrupted by the second diaphragm 86 and the rest of the second regulating assembly 62). Furthermore, isolating the orifice constriction member 206 and its center aperture 208 from the second diaphragm 86 can provide a gain to the outlet flow of the gas (i.e., greater gas flow) because the distance and isolation can cause the second regulator portion 10b to remain fully open with less pressure differential between the inlet to the center aperture 208 and the outlet to the center aperture 208. Furthermore, an excess flow device 300 can be located directly before the inlet to the center aperture 208 or in the center aperture 208 that can be used to reduce the flow of gas in the event of excessive gas flow. The excess flow device 300 can be of a ball 302 and spring 304 design as illustrated in
Furthermore, it should be noted that in the event there is no downstream demand from the regulator for gas, gas pressure increases first inside the lower second area 68 and the first area lower portion 70 of the second regulator cavity 64 and then the first regulator cavity 36 until the sealing discs form a seal on the orifice constriction member and the constriction, respectively, causing a zero flow or lockup condition. In this regard, the described invention also includes a safety feature commonly referred to as pressure control. As described previously, the mechanism of this device operates to control output flow pressure to meet downstream demand. When demand increases, outlet pressure decreases and this results in downward movement of the diaphragms and their related parts, including the stem, causing the discs to move incrementally away from the orifice constriction member and the constriction and thereby allowing more flow through the device to supply the new demand at the same regulated pressure. This continues until the demand is satisfied and an equilibrium state is reached. Conversely, the same events occur in reverse for conditions of decreasing demand. Changes in inlet pressure and/or demand will cause the device to compensate by opening or closing the regulating assembly in response to and in accordance with the new conditions, to again reach an equilibrium state.
The described invention provides consistent repeatable performance over a wide range of inlet pressures and flow rates while also enabling significant reduction in orifice diameter and in diaphragm and overall regulator size. Furthermore, it accomplishes this by use of a simplified mechanism that is less expensive to manufacture and assemble, while at the same time providing better operating results due to the novel design, which substantially reduces function and regulating inaccuracies due to mechanical tolerance variations and lost motion inherent in less directly acting mechanisms which characterize the prior art.
The foregoing detailed description is considered that of a preferred embodiment only, and the particular shape and nature of at least some of the components in this embodiment are at least partially based on manufacturing advantages and considerations as well as on those pertaining to assembly and operation. Modifications of this embodiment may well occur to those skilled in the art and to those who make or use the invention after learning the nature of this preferred embodiment, and the invention lends itself advantageously to such modification and alternative embodiments. For example, a threaded outlet connection can be used instead of a barbed outlet. Furthermore, the regulator can include relief valves for releasing excess gas to the atmosphere. Additionally, the second regulator portion 10b could include an adjustable spring such as that disclosed in U.S. patent application Ser. No. 11/048,532 entitled PRESSURE REGULATOR WITH IMPROVED OUTLET PRESSURE CONTROL and U.S. Pat. No. 6,971,403 entitled DIRECT-ACTING PRESSURE REGULATOR, the entire contents of which are hereby incorporated herein by reference.
Therefore, it is to be understood that the embodiment shown in the drawings and described above is provided principally for illustrative purposes and should not be used to limit the scope of the invention.
| Number | Date | Country | |
|---|---|---|---|
| 60802633 | May 2006 | US |
