Apparatus and method for controlling fluid flow

Abstract

An actuator base, bobbin, and pole piece form a pocket for an armature that a flexible membrane encloses to form an armature chamber filled with an incompressible fluid. The membrane protects the armature from exposure to corrosive fluids flowing in a conduit. Conduit flow can be stopped by driving the membrane against a valve seat. Pressure from the controlled fluid in the conduit is transmitted through the membrane to the fluid within the armature chamber so that the armature does not need to counteract force applied to the membrane by the conduit fluid's pressure.

Description

[0001] This application is a divisional application of U.S. application Ser. No. 10 / 421,359 filed on Apr. 23, 2003, which is a continuation of PCT Application PCT / US01 / 51098 filed on Oct. 25, 2001, which is a continuation-in part of U.S. application Ser. No. 09 / 696,154 filed on Oct. 25, 2001, entitled “Ferromagnetic / Fluid Valve Actuator.” This application is also a continuation-in part of U.S. application Ser. No. 09 / 924,130, filed on Aug. 7, 2001, entitled “Reduced-Energy Consumption Actuator.” This application is also a continuation-in part of U.S. application Ser. No. 10 / 037,473, filed on Oct. 19, 2001, which in turn is a continuation of U.S. application Ser. No. 09 / 514,491, filed on Feb. 29, 2000, now U.S. Pat. No. 6,305,662, entitled “Reduced-Energy Consumption Actuator.” The above-cited applications are incorporated by reference for all purposes.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to controlling fluid flow in variou...

AI Technical Summary

Benefits of technology

[0021] The present design reduces the energy waste that usually occurs in driving the actuator's armature. An armature sensor monitors the armature movement or determines when the armature has reached the end of its travel. At a selected point, based on a signal from the armature sensor, a drive signal to the actuator-coil drive ends. This can reduce energy consumption greatly, because coil-drive duration thereby does not always need to be long enough to meet worst-case requirements usually applied when there is no armature sensor. This can result in a significant battery-longevity increase.

[0022] According to another aspect, the valve actuator can use materials with a high magnetic permeability such as the ferromagnetic types of stainless steel regardless of their low corrosion-resistivity and the armature does not need to be subjected to a number of treatment steps to afford an acceptable level of corrosion resistance. Thus, the present design reduces valve cost, or reduces the greater solenoid-wire size required because the armature's permeability is not as great as optimally possible.

[0023] In one preferred embodiment, we secure a flexible membrane over the end of the pocket in which the armature travels as to protect the armature's high-permeability material from exposure to the possibly corrosive fluid whose flow the valve is to control. Furthermore, we fill the armature pocket with an incompressible fluid so as to counterbalance the force exerted by the controlled fluid's pressure. We improve various prior art designs, for example by eliminating various problems such as that of U.S. Pat. No. 5,941,505 to Nagel to prevent leaks in membranes that protect the controlled fluids from valve-assembly contaminants.

Problems solved by technology

In non-latching actuators, unnecessarily high drive current for holding the valve open also may unnecessarily reduce the battery's longevity.

This usually causes degradation of the armature (i.e., corrosion) and problems with metal and other ions (or other deposits) that accumulate within the bobbins cavity.

However, materials with very high magnetic permeability have usually low corrosion resistance.

Thus, designers in the past have had to compromise permeability for corrosion resistance.

For example, carbon steel has a high magnetic permeability, but is quite vulnerable to rust and corrosion.

Still, the designers have had problems with the above-described deposits, or conversely problems with preventing fluid contamination by the armature, bobbin or other valve elements.

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