Valve subassembly

Abstract

A valve subassembly includes a body plug, a poppet, and a valve seat support. The body plug includes a tubular sidewall, the tubular sidewall defining a central cavity and one or more lateral flow apertures in the sidewall. The poppet includes an axially extending upper stem portion and a lower stem portion and a radially extending poppet sealing portion between the upper stem portion and the lower stem portion, wherein the lower stem portion and the poppet sealing portion are received in the central cavity of the body plug. The valve seat support is assembled with the body plug and includes a central hole, the central hole receives the upper stem portion of the poppet therethrough, and the valve seat support maintains the valve seat seal in radial alignment with the poppet sealing portion.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and all benefits of U.S. Provisional Patent Application No. 63 / 158,408, filed on March 9, 2021, entitled POPPET AND SEAT CARTRIDGE VALVESUBASSEMBLY, and U.S. Provisional Patent Application No. 63 / 180,166, filed on April 27, 2021, entitled POPPET-STYLE VALVE ARRANGEMENTS, the entire disclosures of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to fluid flow and delivery devices and methods, and more particularly, to poppet valves for controlling fluid flow and delivery. Background Art

[0004] As is well known, poppet valves are used as flow control mechanisms for gaseous and liquid fluid delivery, flow control, and pressure control. A poppet valve arrangement includes an axially movable stem having a sealing portion (e.g., an enlarged disc, a tapered end) that seals against an annular valve seat in a valve passage when the stem is in a closed position and axially separates from the valve seat when the stem is in an open position to permit fluid to flow through the valve passage. Many different types of fluid control devices utilize poppet valve mechanisms, including, for example, diaphragm valves, bellows valves, and pressure regulators. Summary of the invention

[0005] According to an exemplary embodiment of the present disclosure, a valve subassembly includes a body plug, a poppet, and a valve seat bracket. The body plug includes a tubular sidewall, the tubular sidewall defining a central cavity and one or more lateral flow apertures in the sidewall. The poppet includes an axially extending upper stem portion and a lower stem portion and a radially extending poppet sealing portion between the upper stem portion and the lower stem portion, wherein the lower stem portion and the poppet sealing portion are received in the central cavity of the body plug. The valve seat bracket is assembled with the body plug and includes a central hole, the central hole receives the upper stem portion of the poppet passing therethrough, and the valve seat bracket maintains the valve seat seal in radial alignment with the poppet sealing portion.

[0006] According to another exemplary embodiment of the present disclosure, a pressure regulator includes a valve body housing, a valve subassembly, a loading mechanism, and a sensing element. The valve body housing includes a central hole disposed between a first end orifice and a second end orifice. The valve subassembly includes a body plug, a lift, and a valve seat support. The body plug includes a tubular sidewall defining a central cavity and one or more lateral flow apertures in the sidewall. The body plug is installed in the central hole of the valve body so that at least one of the one or more lateral flow apertures is in fluid communication with the first end orifice. The lift includes an axially extending upper stem portion and a lower stem portion and a radially extending lift seal portion between the upper stem portion and the lower stem portion, wherein the lower stem portion and the lift seal portion are received in the central cavity of the body plug. The valve seat support is assembled with the body plug and includes a central hole, the central hole receives the upper stem portion of the lift passing therethrough, and the valve seat support maintains the valve seat seal in radial alignment with the lift seal portion. The loading mechanism is assembled with the valve body housing and is operable to apply a set load force to the poppet to move the poppet downward. The sensing element is disposed between the loading mechanism and the poppet to transmit the load force from the loading mechanism to the poppet, wherein when the fluid pressure in one of the first end orifice and the second end orifice exceeds a pressure setting corresponding to the set load force, the sensing element is movable against the set load force to permit the poppet to move upward.

[0007] According to another exemplary embodiment of the present disclosure, a method for replacing a poppet and a valve seat seal in a regulator valve assembly is contemplated. In the exemplary method, a regulator valve assembly is provided, the regulator valve assembly comprising a valve body and a valve subassembly, the valve body having a valve body housing defining a central hole, the valve subassembly comprising a body plug and a valve seat support, the body plug and the valve seat support being assembled together to retain the poppet and the valve seat seal therebetween, wherein the body plug is installed in the central hole. The valve subassembly is removed from the valve body by the following steps: the body plug is removed from the valve body housing, thereby removing the body plug, the valve seat support, the poppet and the valve seat seal from the central hole. The replacement valve subassembly is assembled with the regulator valve body to install a new poppet and valve seat seal in the valve body housing hole. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a cross-sectional schematic diagram of a poppet-type valve assembly according to an exemplary embodiment of the present disclosure;

[0009] Figure 2 is a cross-sectional view of a pressure regulator valve assembly according to another exemplary embodiment of the present disclosure;

[0010] Figure 2A yes Figure 2 an exploded perspective view of a pressure regulator valve assembly;

[0011] Figure 3 yes Figure 2 a cross-sectional view of a valve subassembly of a pressure regulator valve assembly;

[0012] Figure 4 is a cross-sectional view of a pressure regulator valve assembly according to another exemplary embodiment of the present disclosure;

[0013] Figure 4A yes Figure 4 an exploded perspective view of a pressure regulator valve assembly; and

[0014] Figure 5 yes Figure 4 A cross-sectional view of a valve subassembly of a pressure regulator valve assembly. DETAILED DESCRIPTION

[0015] This detailed description describes only exemplary embodiments and is not intended to limit the scope of the claims in any way. In fact, the claimed invention is broader than the exemplary embodiments and is not limited thereto, and the terms used in the claims have their full ordinary meaning. For example, although the specific embodiments described herein relate to pressure reducing regulator valve arrangements, the features of the present application may be applied in addition or alternatively to other types of valves, including, for example, back pressure regulator valve arrangements, stop valves, check valves, and pressure relief valves. The terms "lift valve" and "lift-type valve" as used herein are intended to broadly include any valve having a rod, the rod support being transformed into a sealing member that is sealed and engaged with an annular valve seat by the longitudinal movement of the rod. In addition to airtight or liquid-tight seals, the terms "seal" and "sealed engagement" are intended to include situations where the flow rate is reduced due to contact between the sealing surface and the seating surface.

[0016] Although various creative aspects, concepts and features of the present invention may be described and shown herein as embodied in combination in exemplary embodiments, these various aspects, concepts and features may be used individually or in various combinations and sub-combinations thereof in many alternative embodiments. Unless expressly excluded herein, all such combinations and sub-combinations are intended to fall within the scope of the present invention. In addition, although various alternative embodiments (such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives to form, assembly and function, etc.) may be described herein about various aspects, concepts and features of the present invention, such description is not intended to be a complete or exhaustive enumeration of available alternative embodiments (whether currently known or later developed). Those skilled in the art may easily incorporate one or more of the creative aspects, concepts or features into additional embodiments and uses within the scope of the present invention, even if such embodiments are not explicitly disclosed herein. In addition, although some features, concepts or aspects of the present invention may be described herein as preferred arrangements or methods, such description is not intended to imply that such features are necessary or essential unless expressly stated so. In addition, exemplary or representative values ​​and ranges may be included to assist in understanding the present disclosure, however, such values ​​and ranges should not be interpreted in a limiting sense, but are intended to be critical values ​​or ranges only if explicitly stated. Unless otherwise explicitly stated, a parameter identified as "approximately" or "about" a specified value is intended to include the specified value, the value within 5% of the specified value, and the value within 10% of the specified value. In addition, it should be understood that the drawings of the present application may but need not be drawn to scale, and therefore can be understood to teach various ratios and proportions apparent in the drawings. In addition, although various aspects, features, and concepts may be explicitly identified herein as being inventive or forming part of the present invention, such identification is not intended to be exclusive, but there may be inventive aspects, concepts, and features that are fully described herein but not explicitly identified as such or identified as part of a specific invention, and the present invention is instead set forth in the appended claims. The description of an exemplary method or process is not limited to including all steps required in all cases, and the order in which the steps are presented should not be interpreted as being necessary or essential unless explicitly stated as such.

[0017] refer to Figure 1In the schematically illustrated exemplary embodiment, the poppet-type valve assembly 10 includes a valve body 20 defining a valve passage 22 between an inlet orifice 21 and an outlet orifice 23, and an annular valve seat 30 extending around an axially extending central portion 24 of the valve passage. A poppet 40 is assembled with the valve body 20 and includes an axially extending poppet stem 41 and a radially extending poppet sealing portion 42. An actuator 50 is assembled with the poppet stem 41 to control axial movement of the poppet 40 between a closed position, in which the poppet sealing portion 42 seals against the valve seat 30 (e.g., to prevent flow exceeding an allowable leakage rate), and an open position, in which the poppet sealing portion is axially separated from the valve seat to permit fluid to flow through the axially extending portion 24 of the valve passage 22. The actuator 50 may be user-operable (e.g., manually, pneumatically, or electrically) for selectively moving the poppet 40. Alternatively, the actuator 50 may be configured to automatically move the poppet or permit movement of the poppet under certain predetermined system conditions. For example, the actuator arrangement may be configured to cause or permit the poppet 40 to automatically move at a threshold system fluid pressure, such as to release excess fluid pressure from the system (in the case of a pressure relief valve), prevent backflow (in the case of a check valve), or reduce outlet pressure (in the case of a pressure regulator). Examples of pressure regulators with poppet-type valve arrangements are disclosed in a product catalog titled PRESSURE REGULATORS RHPS SERIES (MS-02-430, Rev K, May 2020), which is publicly available online and otherwise from Swagelok Company and is fully incorporated herein by reference.

[0018] The valve seat and poppet sealing surfaces of valves, such as regulator valves, are often sensitive to contamination and prone to wear, especially in high cycle applications. According to an exemplary aspect of the present disclosure, a valve can have a poppet and valve seat subassembly that facilitates replacement of the poppet and valve seat seal while preventing the poppet and valve seat sealing surfaces from being touched by a user.

[0019] Figure 2 and Figure 2AAn exemplary pressure reducing regulator valve assembly 100 is shown, comprising: a regulator valve body 110, the regulator valve body defining a valve passage 112 between a first end (e.g., inlet) orifice 111 and a second end (e.g., outlet) orifice 113; and an annular valve seat seal 135 disposed in the valve body between the inlet orifice and the outlet orifice. A poppet 140 is assembled with the valve body 110 and comprises an axially extending upper stem portion 141 and a lower stem portion 143 and a radially extending poppet sealing portion 142 between the upper stem portion and the lower stem portion. The poppet 140 is axially movable between a lower open position, in which the poppet sealing portion is axially spaced from the valve seat seal 135, and an upper closed position, in which the poppet sealing portion is sealingly engaged with the valve seat seal.

[0020] According to an exemplary aspect of the present disclosure, a regulator valve assembly 100 includes a valve subassembly 101 (also shown in Figure 3 ), the valve subassembly is configured to facilitate removal and replacement of the poppet 140 and the seat seal 135, for example, to replace worn or damaged sealing surfaces. In the illustrated example, the valve subassembly 101 includes: a body plug 120 having a tubular sidewall 121 defining a central cavity 122 that receives a sealing portion 142 and a lower stem portion 143 of the poppet 140; and a seat seal retaining seat support 130 that is assembled with the body plug over the poppet 140 to hold the poppet and the seat seal 135 together as a replaceable valve subassembly.

[0021] The valve seat support 130 includes an externally threaded lower end portion 134, which is threadedly connected to the internally threaded upper end portion 124 of the body plug 120, wherein the lower end portion of the valve seat support engages the upper countersunk hole 122-1 in the body plug cavity 122, and the upper stem portion 141 of the poppet 140 extends into the central hole 131 of the valve seat support. The valve seat seal 135 is fixed or retained by the lower end portion 134 of the valve seat support 130 (e.g., nailed into the lower end portion, integral with the lower end) to be radially aligned with the poppet seal portion 142 for engagement with the poppet seal portion when the poppet 140 is in the closed position.

[0022] The body plug 120 is configured to be installed in the central bore 114 in the body housing 115 to form the valve body 110. The exemplary body plug 120 includes one or more transverse apertures 123 in the sidewall 121 positioned to align with the valve body inlet aperture 111, and the exemplary valve seat support 130 includes one or more transverse apertures 133 positioned to align with the valve body outlet aperture 113 to allow fluid flow to flow from the inlet aperture into the body plug cavity 122 and between the poppet seal portion 142 and the valve seat seal 135 to flow to the outlet when the poppet 140 is in the open position. The apertures 123, 133 can be circumferentially spaced around the body plug 120 and the valve seat support 130, respectively, for example, to ensure that the inlet aperture 111 and the outlet aperture 113 are at least partially aligned with at least one of the apertures 123, 133 regardless of the rotational position of the body plug 120 and the valve seat support 130 in the valve body housing 115. In addition, the body plug 120 can have an annular recess 123-1 that intersects the body plug aperture 123, for example, to provide a fluid flow path between the body plug aperture and the inlet orifice 111, regardless of any misalignment of the body plug aperture and the inlet orifice. The valve seat support hole 131 can have a tapered inner surface 131-1, for example, to facilitate expansion of gas flowing through the valve seat support hole.

[0023] O-ring / gasket seals 127 (and backup rings, not shown) are disposed in grooves 126 in body plug 120 to provide an airtight body seal between inlet orifice 111 and the lower end of central bore 114 and between the inlet orifice and outlet orifice 113. One or more O-ring / gasket seals 137 (and backup rings, not shown) may be disposed in grooves 136 in valve seat holder 130 to provide an airtight seal between outlet orifice 113 and loading mechanism 150 (described in more detail below).

[0024] Many different arrangements can be provided for securely mounting the body plug 120 in the body housing 115. For example, the externally threaded portion 128 of the body plug 120 can be threadedly connected to the internally threaded portion 118 of the central bore 114. Figure 2A As shown in the exploded perspective view of , the end portion of the body plug 120 may have a flat surface 120-1 to be engaged and tightened by a tool (e.g., a torque wrench). Additionally or alternatively, the end portion of the body plug 120 may have other tool engagement features, such as a hole 120-2 for engaging with a plug wrench.

[0025] Thus, in an exemplary method of replacing the poppet 140 and the seat seal 135 in the regulator valve assembly 100 (e.g., to replace worn / damaged sealing surfaces), the valve subassembly 101 (including the body plug 120 and the seat support 130, which are assembled with the seat support to retain the poppet 140 and the seat seal 135 therebetween) is removed from the regulator valve body 110 by the following steps: the body plug is disassembled (e.g., unscrewed) from the regulator valve body housing 115, thereby removing the body plug, the seat support, the poppet, and the seat seal from the central bore 114 of the regulator valve body housing. A replacement valve subassembly, which may (but need not be) substantially identical to the removed valve subassembly, is then assembled with the regulator valve body to install a new poppet 140 and seat seal 135 in the regulator valve body bore 114.

[0026] In other embodiments, the valve subassembly may include a body plug that is secured to the valve body via a bolting arrangement, for example, to reduce the installation torque required during assembly / disassembly. Figure 4 and Figure 4A An exemplary pressure reducing regulator valve assembly 200 is shown, comprising: a regulator valve body 210, the regulator valve body defining a valve passage 212 between a first end (e.g., inlet) orifice 211 and a second end (e.g., outlet) orifice 213; and an annular valve seat seal 235 disposed in the valve body between the inlet port and the outlet port. A poppet 240 is assembled with the valve body 210 and comprises an axially extending upper stem portion 241 and a lower stem portion 243 and a poppet sealing portion 242 extending radially between the upper stem portion and the lower stem portion. The poppet 240 is axially movable between a lower open position, in which the poppet sealing portion is axially spaced from the valve seat seal 235, and an upper closed position, in which the poppet sealing portion is sealingly engaged with the valve seat seal.

[0027] The regulator valve assembly 200 includes a valve subassembly 201 (also shown in Figure 5), the valve subassembly is configured to facilitate removal and replacement of the poppet 240 and the seat seal 235, for example, to replace worn or damaged sealing surfaces. In the illustrated example, the valve subassembly 201 includes: a body plug 220 having a tubular sidewall 221 that defines a central cavity 222 that receives a sealing portion 242 and a lower stem portion 243 of the poppet 240; and a seat seal retaining seat support 230 that is assembled with the body plug on the poppet 240 to hold the poppet and the seat seal 235 together as a replaceable valve subassembly 201.

[0028] The valve seat support 230 includes an externally threaded lower end portion 234 that is threadedly connected to the internally threaded upper end portion 224 of the body plug 220. In the illustrated embodiment, the valve seat support 230 has an extension or sealing cover 232 that sits on the lower end portion of the valve seat support and engages the first upper countersunk hole 222-1 in the body plug cavity 222. By providing the valve seat support as a two-part configuration, the surface features of the valve seat support (e.g., the tapered inner surface 231-1 described below) can be more easily manufactured. The upper stem portion 241 of the poppet 240 extends into the central hole 231 of the valve seat support 230. Although the seat seal may be stapled to the seat support or the seat support sealing cap, in the illustrated embodiment, the seat seal 235 is provided as a separate sealing ring secured between the seat support sealing cap 232 and the second upper counterbore 222-4 in the body plug cavity for engagement with the poppet sealing portion when the poppet 240 is in the closed position. As shown, the seat seal 235 may have a groove that retains a gasket / O-ring seal in sealing engagement with the seat support sealing cap 232 and the second upper counterbore 222-4.

[0029] Although many different types of sealing rings may be used, in the illustrated embodiment, the sealing ring 235 may be provided as an overmolded, overlaid, or otherwise interlocked annular softer material (e.g., having a hardness of less than about 100 HRM) sealing ring that is fixed to or retained (e.g., press-fit, assembled on, injection molded or overmolded to, or 3D printed to) a harder (e.g., having a hardness of greater than about 80 HRB) inner circumferential rib, flange, rail, or other such protrusion that protrudes into the central portion of the valve passage. The rigid underlying protrusion allows the use of a relatively thin (e.g., between about 0.05 inches and about 0.10 inches) sealing ring, thereby minimizing thermal expansion, material flow, and deformation of the softer sealing ring material, while providing rigid support for use in higher pressure (e.g., up to about 6000 psi) applications. Any suitable material may be used to provide adequate sealing performance within the valve. For example, the sealing ring may be provided by a suitable plastic (e.g., PEEK), and the sealing ring retaining protrusion may be provided by a metal (e.g., stainless steel). The gasket / O-ring seal may be formed of a suitable elastomer, such as EPDM, perfluoroelastomer, or nitrile. An exemplary valve seat seal ring having an interlocking seal portion is described in co-pending U.S. Provisional Patent Application No. 63 / 180,166, entitled POPPET-STYLE VALVE ARRANGEMENTS, the entire disclosure of which is incorporated herein by reference.

[0030] The body plug 220 is configured to be installed in the central hole 214 in the body housing 215 to form the valve body 210. The exemplary body plug 220 includes one or more transverse apertures 223 in the side wall 221 positioned to align with the valve body inlet orifice 211, and the exemplary valve seat support 230 includes one or more transverse apertures 233 positioned to align with the valve body outlet orifice 213 to allow fluid flow to flow from the inlet orifice 211 into the body plug cavity 222 and flow between the poppet seal portion 242 and the valve seat seal 235 to flow to the outlet 213 when the poppet 240 is in the open position. The apertures 223, 233 may be spaced circumferentially around the body plug 220 and the valve seat holder 230, respectively, for example, to ensure that the inlet orifice 211 and the outlet orifice 213 are at least partially aligned with at least one of the apertures 223, 233 regardless of the rotational position of the body plug 220 and the valve seat holder 230 in the valve body housing 215. In addition, the body plug 220 may have an annular recess 223-1 that intersects the body plug aperture 223, for example, to provide a fluid flow path between the body plug aperture and the inlet orifice 211 regardless of any misalignment of the body plug aperture with the inlet orifice.

[0031] O-ring / gasket seals (e.g., gaskets and backup rings) 227 are disposed in grooves 226 in body plug 220 to provide an airtight body seal between inlet orifice 211 and the lower end of central bore 214 and between the inlet orifice and outlet orifice 213. One or more O-ring / gasket seals (e.g., with backup rings) 237 may be disposed in grooves 236 in valve seat holder 230 to provide an airtight seal between outlet orifice 213 and loading mechanism 250 (described in more detail below).

[0032] Many different arrangements can be provided for securely mounting the body plug 220 in the body housing 215. In the illustrated embodiment, a mounting plate 225 is secured to the lower end of the body plug 220, such as by mounting bolts 205, to secure the body plug to the body housing 215 when the tubular sidewall 221 is axially inserted into the body housing bore 214. In other embodiments, the mounting plate can be integrally formed with the body plug, welded to the body plug, or otherwise attached to the body plug. Figure 4A As shown, the mounting plate 225 includes a circle of mounting holes 225-1 that align with the body housing mounting holes 215-1 to receive the mounting bolts 207 to secure the body plug 220 to the valve body housing 215 when the body plug 220 is inserted into the body housing hole 214. The mounting holes 225-1 can be equally spaced around the mounting plate 225 to allow the mounting plate to be attached to the valve body housing 215 in multiple orientations. Alternatively, the mounting plate and body housing mounting holes 225-1, 215-1 can be arranged to ensure installation in a single orientation.

[0033] In an exemplary method of replacing the poppet 240 and the seat seal 235 in the regulator valve assembly 200 (e.g., to replace worn / damaged sealing surfaces), the valve subassembly 201 (including the body plug 220 and the seat support 230, which are assembled together to retain the poppet 240 and the seat seal 235 therebetween) is removed from the regulator valve body 210 by removing the mounting bolts 207 from the mounting plate and body housing mounting holes 225-1, 215-1 and removing the body plug, seat support, poppet and seat seal from the central bore 214 of the regulator valve body housing 215. A replacement valve subassembly 201, which may (but need not be) substantially identical to the removed valve subassembly, is then assembled with the regulator valve body housing 215 by axially inserting the tubular end portion 221 of the body plug 220 into the body housing bore 214. As shown, the upper or front end portions of the seat support 230 and the body plug 220 may have tapered or chamfered surfaces 230-1, 230-2, 221-1, for example, to facilitate alignment and insertion of the seat support and the body plug. The body plug 220 is then secured by mounting bolts 207 installed through aligned mounting holes 225-1, 215-1 in the mounting plate 225 and the body housing 215 to secure the new poppet 240 and seat seal 235 in the regulator valve body bore 214.

[0034] The regulator valve assembly may include a sensing element (e.g., diaphragm, piston) on which fluid pressure (e.g., pressurized fluid in the outlet orifice of a pressure reducing regulator) may resist a loading force applied by a loading mechanism (e.g., bias spring, pressurized "dome" chamber) to move the sensing mechanism, and therefore the poppet, when the fluid pressure exceeds a pressure setting. Although the poppet in the poppet and seat valve subassembly may extend beyond the seat support to engage with an external sensing element, in the illustrated embodiment, the piston sensing element 180, 280 is assembled with the central hole 131, 231 of the seat support 130, 230, stacked above the upper stem portion 141, 241 of the poppet 140, 240. One or more O-ring / gasket seals (e.g., with a backup ring) 187, 287 may be disposed in the groove 186, 286 in the piston 180, 280 to seal the valve seat holder hole 131, 231, thereby providing an airtight seal between the outlet orifice 113, 213 and the loading mechanism 150, 250. The piston 180, 280 may have a shoulder portion 188, 288 that engages the counterbore 138, 238 in the valve seat holder 130, 230 to retain the piston 180, 280 with the valve subassembly 101, 201.

[0035] A loading mechanism (e.g., a fluid pressurized chamber or dome loading mechanism 150, 250, as shown) applies a downward force to the poppet 140, 240 through the piston 180, 280 to bias the poppet toward the open position. The outlet orifice 113, 213 is in fluid communication with the piston 180, 280 so that the pressurized fluid in the outlet orifice applies an upward force to the piston. In this arrangement, when the outlet orifice pressure exceeds the set pressure, the upward fluid pressure applied to the piston 180, 280 exceeds the downward loading mechanism force, causing the piston to move upward, thereby allowing the poppet 140, 240 to move to the closed position.

[0036] As shown, the poppet 140, 240 may have an internal passage 145, 245 extending from the lower stem portion 143, 243 of the poppet to the upper portion of the poppet downstream (i.e., above) the valve seat seal 135, 235, wherein the gasket seal 147, 247 (in the groove 146, 246) provides a seal between the lower stem portion of the poppet and the narrower base portion 122-2, 222-2 of the body plug cavity 122, 222, so that when the poppet 140, 240 is in the closed position, the inlet or upstream fluid pressure to which the poppet is subjected is offset by the outlet or downstream fluid pressure. This arrangement may be referred to as a balanced poppet design, which may be used, for example, to reduce valve seat loads, for example, to reduce wear / deformation of the valve seat. In this arrangement, the poppet spring 148, 248 can be disposed in the body plug cavity 122, 222, compressed between the lower counterbore 122-3, 222-3 and the poppet 140, 240 (e.g., at the shoulder 144, 244) to provide a consistent closing / sealing force on the poppet, regardless of the system fluid pressure.

[0037] To assemble Figure 2 , Figure 2A and Figure 3 In the exemplary valve subassembly 101, the poppet 140 and the poppet spring 148 are inserted into the central cavity 122 of the body plug 120, wherein the lower stem portion 143 of the poppet is received in the narrower base portion 122-2 of the body plug cavity 122, and the poppet spring engages the lower countersunk hole 122-3 of the body plug cavity. The piston 180 is installed from the bottom end through the central hole 131 of the valve seat support 130, wherein the lower shoulder portion 188 of the piston engages the countersunk hole 138 in the valve seat support. The valve seat support 130 and the pinned valve seat seal 135 are threadedly assembled with the body plug 120, wherein the lower end portion 134 of the valve seat support engages the upper countersunk hole 122-1 in the body plug cavity 122.

[0038] To assemble Figure 4 , Figure 4A and Figure 5In the exemplary valve subassembly 201, a poppet 240 and a poppet spring 248 (fixed with the poppet 240 using a retaining ring 249) are inserted into the central cavity 222 of the body plug 220, wherein the lower stem portion 243 of the poppet is received in the narrower base portion 222-2 of the body plug cavity 222, and the poppet spring engages the lower counterbore 222-3 of the body plug cavity. The piston 280 is installed from the bottom end through the central hole 231 of the valve seat support 230, wherein the lower shoulder portion 288 of the piston engages the counterbore 238 in the valve seat support. The valve seat seal assembly 235 and the valve seat support sealing cap 232 are inserted into the body plug counterbore 222-4, 222-1, and the valve seat support 230 is threadedly assembled with the body plug 220 so that the valve seat seal assembly is sealingly fixed between the valve seat support extension and the second upper body plug counterbore 222-4.

[0039] Many different types of loading mechanisms may be utilized to apply a selected downward biasing force to the sensing element. In the illustrated example, the piston sensing dome loading arrangement 150, 250 includes: upper and lower dome housing shell members 151-1, 251-1, 151-2, 251-2 (e.g., secured together by bolts 102, 202), the dome housing shell members being assembled with the valve body housing 115, 215 (e.g., by mounting screws 103, 203) to define a dome chamber 152, 252; and a dome loading diaphragm 159, 259 having an outer periphery captured between the upper shell member and the lower shell member, wherein the diaphragm screw 154, 254 is mounted through a central opening in the dome loading diaphragm and positioned to engage the upper end portion 186, 286 of the piston 180, 280. In the example shown, support plates 155-1, 255-1, 155-2, 255-2 are secured to diaphragm screws 154, 254 above and below the dome loading diaphragms 159, 259 by nuts 156, 256 to provide additional support to the diaphragms. The upper dome housing shell member 151-1, 251-1 includes a pressurized port 153, 254 (e.g., defined by a welded end cap 151-3, 251-3) for supplying pressurized fluid at a set pressure (e.g., from a secondary pressure regulator) to the dome chamber 152, 252 to apply a corresponding load force to the dome loading diaphragm 159, 259, thereby causing the diaphragm screw 154, 254 to move against the piston 180, 280. In another exemplary embodiment, the actuator arrangement may include a compression spring that applies a downward biasing force (directly or indirectly) to the diaphragm. In one such embodiment, the compression of the spring can be adjustable to increase or decrease the downward biasing force applied by the spring. For example, a spring guide engaging the upper end of the spring can be lowered or raised (e.g., by a rotatable knob or handle) to increase or decrease the compression of the spring. Exemplary dome pressurization and spring loading arrangements are described in the PRESSURE REGULATORS RHPS SERIES catalog incorporated above. Other types of sensing mechanisms can also be used in place of the exemplary piston, such as a diaphragm element or piston element external to the valve subassembly, as described in the PRESSURE REGULATORS RHPS SERIES catalog incorporated above.

[0040] The inventive aspects have been described with reference to exemplary embodiments. Modifications and alterations will occur to others upon reading and understanding this specification. All such modifications and alterations are intended to be included as long as they are within the scope of the appended claims or their equivalents.

Claims

1. A valve subassembly, the valve subassembly comprising: a body plug comprising a tubular sidewall defining a central cavity and one or more lateral flow apertures in the sidewall; a lift member including an axially extending upper and lower stem portions and a radially extending lift member sealing portion between the upper and lower stem portions, wherein the lower stem portion and the lift member sealing portion are received in the central cavity of the body plug; a valve seat support including a central bore that receives the upper stem portion of the poppet therethrough, the valve seat support maintaining a valve seat seal in radial alignment with the poppet seal portion; and a piston assembled with the central hole of the valve seat support and including a lower end portion engaging the upper stem portion of the poppet and an upper end portion extending above the valve seat support; The valve seat support is assembled with the body plug to hold the poppet, the valve seat seal and the piston together with the valve seat support and the body plug as a replaceable valve subassembly.

2. The valve subassembly of claim 1, wherein the valve seat support is threadably assembled with the body plug.

3. The valve subassembly of claim 1, wherein the valve seat support includes one or more cross-flow apertures.

4. The valve subassembly of claim 1, wherein the valve seat seal is pinned into a lower end portion of the valve seat support.

5. The valve subassembly of claim 1 further comprising a poppet spring disposed in the central cavity of the body plug, the poppet spring applying an upward biasing force to the poppet to sealingly engage the valve seat seal.

6. The valve subassembly of claim 1, wherein the piston includes a shoulder portion that engages a countersunk bore in the central bore of the valve seat holder to retain the piston with the valve seat holder.

7. A valve, comprising: a valve body housing including a central bore disposed between the first end aperture and the second end aperture; as well as The valve subassembly of claim 1, wherein said body plug is mounted in said central bore of said valve body such that at least one of said one or more cross-flow apertures is in fluid communication with said first end port.

8. The valve of claim 7, wherein the body plug is threadably assembled with the central bore of the valve body housing.

9. The valve of claim 7, wherein the body plug includes an end flange secured to the valve body housing.

10. A pressure regulator, comprising: a valve body housing including a central bore disposed between the first end aperture and the second end aperture; The valve subassembly as claimed in claim 1; as well as a loading mechanism assembled with the valve body housing and operable to apply a set load force to the poppet to move the poppet downward; and The piston of the valve subassembly acts as a sensing element, which is disposed between the loading mechanism and the lifting member of the valve subassembly to transfer the load force from the loading mechanism to the lifting member, wherein when the fluid pressure within one of the first end orifice and the second end orifice exceeds the pressure setting corresponding to the set load force, the sensing element is capable of moving against the set load force to allow the lifting member to move upward.

11. The pressure regulator of claim 10, wherein the valve seat support is threadably assembled with the body plug.

12. The pressure regulator of claim 10, wherein the valve seat support includes one or more cross-flow apertures.

13. The pressure regulator of claim 10, wherein the valve seat seal is pinned into a lower end portion of the valve seat support.

14. The pressure regulator of claim 10, further comprising a poppet spring disposed in the central cavity of the body plug, the poppet spring applying an upward biasing force to the poppet to sealingly engage the valve seat seal.

15. The pressure regulator of claim 10, wherein the piston includes a shoulder portion that engages a countersunk bore in the central bore of the valve seat holder to retain the piston with the valve seat holder.

16. The pressure regulator of claim 10, wherein the body plug is threadably assembled with the central bore of the valve body housing.

17. The pressure regulator of claim 10, wherein the body plug includes an end flange secured to the valve body housing.

18. A method of replacing a poppet and a seat seal in a regulator valve assembly, the method comprising: providing a regulator valve assembly, the regulator valve assembly comprising a valve body and a valve subassembly as claimed in claim 1, the valve body having a valve body housing defining a central bore, wherein the body plug of the valve subassembly is mounted in the central bore; The valve subassembly is removed from the valve body by: removing the body plug from the valve body housing, thereby removing the body plug, the valve seat support, the poppet, the piston and the valve seat seal from the central bore; and A replacement valve subassembly is assembled with the regulator valve body to install a new poppet, piston and seat seal in the valve body housing bore.

19. The method of claim 18, wherein the body plug includes an externally threaded outer portion and the central bore includes an internally threaded portion, wherein removing the body plug from the valve body housing includes unthreading the body plug from the central bore.

20. The method of claim 18, wherein the body plug includes a mounting plate extending from an end portion of the body plug, wherein removing the body plug from the valve body housing includes removing mounting bolts securing the mounting plate to the valve body housing.

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