Regulator with improved adjustment

Abstract

An inner component assembly for a regulator can include a cage and a plug assembly. The cage can include a peripheral wall defining an opening and a plurality of cage holes formed in the peripheral wall. The plug assembly can include a plug and a sealing element and can be configured to be movably received within the opening such that the sealing element selectively contacts an inner surface of the cage to vary a flow area through the plurality of cage holes depending on a position of the plug.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 17 / 501,289, filed October 14, 2021, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Regulators can be used to regulate pressure and control flow rate for fluid distribution. In particular, some regulators can be service regulators, which can be configured to reduce the pressure of fluid (e.g., natural gas) from a high-pressure main pipeline and control the flow rate of the fluid to meet downstream demand while keeping the downstream pressure within a desired range. Summary of the Invention

[0004] Examples of the disclosed technologies can provide improved regulators, including service regulators for distributing fluids such as natural gas.

[0005] According to some aspects of this disclosure, a regulator may include a regulator body defining an inlet and an outlet, and a seat disposed within the regulator body. The seat may be disposed along a flow path between the inlet and the outlet. The regulator may also include a plug assembly and a cage. The plug assembly may be movable relative to the seat to regulate flow along the flow path, and may include a plug and a peripheral sealing assembly. The cage may have a peripheral wall that may define a central opening and a cage axis, and may include a plurality of cage orifices that may extend through the peripheral wall. The cage may surround the flow path adjacent to the seat, and may movably receive the plug within the central opening such that the plug assembly is movable along the cage axis. Additionally, the peripheral sealing element may be configured to selectively contact an inner surface of the peripheral wall within a range of travel of the plug assembly to define a flow region of the cage orifices included in the flow path. The flow region may vary depending on the position of the plug assembly along the range of travel.

[0006] In some examples, the plug assembly can be movable between a first position and a second position along the travel range, where the flow region is a first flow region in the first position and the plug assembly is further away from the seat than in the first position, and the flow region is a second flow region larger than the first flow region in the second position. In the first position, at least a portion of the sealing region of the peripheral sealing element may not be axially aligned with the cage orifice. In the second position, the upstream edge of the sealing region of the peripheral sealing assembly may be axially aligned with the cage orifice.

[0007] The plug assembly can also be movable to a third position along the range of travel at which the plug assembly is further from the seat portion than at the first and second positions. Movement of the plug assembly from the second position to the third position can result in a non-linear increase in the flow area relative to movement of the plug assembly. Optionally or preferably, at least one of the cage apertures can include an upstream portion and a downstream portion. The downstream portion can have a greater circumferential dimension than the upstream portion.

[0008] In some examples, the inner surface of the peripheral wall can define a sealing portion and a clearance portion. The clearance portion can be further from the seat portion than the sealing portion, and the sealing portion can provide a clearance relative to the peripheral seal assembly element that is less than a clearance provided by the clearance portion relative to the peripheral seal assembly. In some cases, a diameter of the inner surface at the sealing portion can be less than a diameter of the inner surface at the clearance portion, and the cage defines a tapered transition portion between the sealing portion and the clearance portion. The peripheral seal assembly can be configured to contact the inner surface along the sealing portion and to be substantially disengaged from the inner surface along the clearance portion.

[0009] In some examples, the peripheral seal assembly can be biased radially outward relative to the plug. The plug assembly can define a circumferential groove and the peripheral seal assembly can be retained by the circumferential groove. In some cases, the peripheral seal assembly can include a ring having an outer diameter that is greater than a diameter of the plug, and one or more resilient members can be disposed within the circumferential groove to bias the ring radially outward from the circumferential groove.

[0010] In some examples, at least one of the cage apertures can include a downstream portion and an upstream portion, where a flow profile of the downstream portion is different than a flow profile of the upstream portion. The downstream portion can include a first portion having a first circumferential width and the upstream portion can include a second portion having a second circumferential width. The first circumferential width can be greater than the second circumferential width and the first portion can be continuous with the second portion.

[0011] In some examples, the cage can be configured to be selectively installed in the regulator body in a first orientation or in a second orientation opposite the first orientation. Depending on whether the cage is installed in the first orientation or the second orientation, the flow area can vary differently as a function of the position of the plug assembly along the range of travel.

[0012] In some examples, the cage aperture includes a plurality of slots extending between the first cage end and the second cage end. Each slot of the plurality of slots can extend axially into a low flow portion of the cage within which the peripheral seal assembly is configured to sealingly contact the inner surface. Optionally or preferably, the plurality of slots can exhibit a plurality of different lengths of axial extension into the low flow portion of the cage. BRIEF DESCRIPTION OF DRAWINGS

[0013] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate examples of the disclosed technology and together with the description, serve to explain principles of examples of the disclosed technology:

[0014] Figure 1 is a cross-sectional view of a regulator according to some examples of the disclosed technology, the regulator including an inner assembly having a cage and a plug assembly in a fully closed configuration;

[0015] Figure 2 is a side view of the cage of Figure 1

[0016] Figure 3 is a cross-sectional view of the cage of Figure 1 taken along line 3-3 of Figure 2 where the cage is flattened to better show certain features;

[0017] Figure 4 is a partial schematic detail cross-sectional view of region 4-4 of the regulator of Figure 1

[0018] Figure 5 is a partial schematic detail cross-sectional view of the regulator of Figure 4 similar to the view of Figure 1 in another closed configuration;

[0019] Figure 6 is a cross-sectional view of the service regulator of Figure 1 in an open configuration;

[0020] Figure 7 is a partial schematic detail cross-sectional view of the service regulator of Figure 1 showing region 7-7 of Figure 6

[0021] Figure 8 is a cross-sectional view of the service regulator of Figure 1 in another open configuration;

[0022] Figure 9 is a partial schematic cross-sectional view of the service regulator of Figure 1 showing region line 9-9 of Figure 8

[0023] is a graph showing flow characteristics provided by the cage of Figure 10 Figure 1

[0024] Figure 11 is an isometric view of another example of a cage according to the disclosed technology;

[0025] ​​​​​Figure 12 is an isometric view of another example of a cage according to the disclosed technology;

[0026] Figure 13 is an isometric view of another example of a cage according to the disclosed technology;

[0027] Figure 14 is a perspective view of another example of a cage according to the disclosed technology;

[0028] Figure 15 is a graph showing Figures 12-14 is a graph showing flow characteristics of the cage shown;

[0029] Figure 16 is a cross-sectional view of another example of a cage according to the disclosed technology; and

[0030] Figure 17 is a cross-sectional view of another example of a cage according to the disclosed technology. DETAILED DESCRIPTION

[0031] Before any examples of the disclosed technology are explained in detail, it is to be understood that the disclosed technology is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosed technology is capable of other examples and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled,” and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

[0032] The following discussion is presented to enable a person skilled in the art to make and use examples of the disclosed technology. Various modifications to the examples shown will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other examples and applications without departing from the examples of the disclosed technology. Thus, the examples of the disclosed technology are not intended to be limited to the examples shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is presented in relation to the attached drawings, wherein like numerals are used to represent like elements throughout the views. The drawings are not necessarily to scale, depict selected examples, and are not intended to limit the scope of examples of the disclosed technology. Skilled artisans will recognize that the examples provided herein have many useful alternatives and fall within the scope of the disclosed technology.

[0033] As noted above, regulators can be used to distribute natural gas or other fluids. In some cases, regulators can be configured to reduce the pressure of the associated fluid from a main line or distribution station, as well as control the flow rate of the natural gas to meet downstream demand while maintaining the downstream pressure within a desired range.

[0034] As cities or other areas expand, demand for natural gas typically increases gradually over a long period of time, often years or even decades. Thus, for natural gas infrastructure installed for a newly developed project, demand can be initially low but significantly increase over time. To address this variation in demand, a regulator can be sized according to current demand (i.e., initial demand), which can result in increased costs in the future and disruption of service when the regulator must be upgraded, or the regulator can be sized to deliver the amount of natural gas required after a certain area is fully developed (i.e., sized according to expected final demand).

[0035] While it is generally preferable to size a regulator to meet final demand, conventional regulators can not have sufficient turndown characteristics (i.e., the ratio of the maximum capacity of the regulator to the minimum flow rate required) to provide stable flow rates under both low demand and high demand conditions. For example, while conventional regulators can be configured to provide high flow rates to meet final demand, the regulator can not be able to effectively operate at very low flow rates to effectively regulate natural gas supply during initial demand. In other words, some conventional regulators can not be able to provide stable flow rates at both high flow rates and low flow rates.

[0036] As one example, known plug-type regulators use a rubber plug that moves relative to an annular seat within the body of the regulator, the rubber plug having an opening for controlling the flow of natural gas. More specifically, when the associated plug assembly is fully closed, the plug seals against the annular seat to prevent the flow of natural gas through the regulator. The plug can then be moved away from the seat to allow natural gas to flow through the regulator via the opening. While such plug-type regulators can operate at high flow rates, the plug must be operated in very close proximity to the seat to achieve low flow rates, which can require very precise control of the position of the plug in a series of very small movements. However, precise and small movements of the plug can be difficult to control, which can result in overall flow metering that is less than optimal or cause pressure cycling that causes the plug to repeatedly contact the seat. In particular, because the plug must be operated in very close proximity to the seat to achieve low flow rates, even a small decrease in demand can cause the plug to inadvertently contact the seat, thereby interrupting the flow of natural gas through the regulator. Thus, contact between the seat and plug that can result from conventional operation at low flow rates can cause undesirable disruptions to the flow of natural gas (or other fluids) through the system.

[0037] In an attempt to mitigate these shortcomings, some plug regulators incorporate cages that surround the plug and include undulating apertures to help control the flow of gas. More specifically, as the plug moves away from the seat, natural gas can flow through the opening of the seat and through at least a portion of the apertures to flow through the regulator. However, the use of these cages does not always reliably achieve the necessary regulation. In particular, in order to allow the plug to operatively move within the cage, a sufficient gap must be provided between the cage and the plug. But this gap can provide an opening that is too large to allow the plug to sufficiently restrict flow through the regulator at low flow rates. For example, the gap can cause a blow-by, in which some natural gas can escape between the plug and the cage rather than passing through the portion of the apertures that is located between the plug and the seat. Moreover, at low flow rates (i.e., high regulation), the size of the flow through the gap between the plug and the cage can be of the same or greater magnitude as the flow through the portion of the apertures that is located between the plug and the seat. Thus, effective operation at low flow rates can result in a disruption of downstream supply, even with the cage in place.

[0038] Other known regulators, particularly boot regulators, dispense with the seat, plug, and cage, and instead use a rubber membrane to control the flow of natural gas, thereby providing the necessary regulation. The membrane can be placed over an opening within the regulator, and the membrane can be partially lifted from the opening to allow natural gas to pass through the regulator. Because only a small portion of the membrane is lifted under certain operating conditions, high regulation can generally be achieved. However, conventional boot regulators often require that the sensitive rubber membrane be positioned directly in the flow path, where it can be susceptible to excessive wear and damage, including from debris entrained in the gas. This damage is common in conventional systems and can result in increased maintenance costs and service disruptions (e.g., replacing damaged membranes as needed).

[0039] Examples of the disclosed technology can provide improvements over conventional plug and boot regulators, including by providing a robust regulator with high regulation to achieve stable flow of fluid at both high and low flow rates. For example, a regulator can include a trim assembly that includes a plug movably received within a cage. The plug can be controllably moved relative to both a seat and the cage of the regulator to control the flow of fluid through a plurality of cage apertures formed in and extending through a peripheral wall of the cage. The plug can also have a seal assembly that can reduce (e.g., eliminate) a gap between the plug and the cage to appropriately restrict the flow of fluid through the cage, while also ensuring that the regulator can be responsively controlled to small changes in demand (as well as small amounts of demand).

[0040] In some examples, a regulator can include a housing having a cap coupled to a regulator body by a plurality of fasteners (e.g., bolts). The regulator body can include an inlet defining an inlet opening and an outlet defining an outlet opening. The inlet and outlet can join together at an orifice to define a flow path through the regulator. As such, the inlet can be an upstream portion of the flow path and the outlet can be a downstream portion of the flow path. Additionally, the regulator can include a seat surrounding the orifice. The seat can define a seating surface and can also be configured to receive a portion of an inner assembly (e.g., a cage). In some examples, the seat can be integrally formed within the regulator body, or the seat can be a separate structure received within the regulator body.

[0041] In some examples, a regulator can include an inner assembly disposed within a regulator (e.g., a regulator body). The inner assembly can be configured to control the flow of fluid through the regulator and can include a ring-shaped cage having a plurality of cage holes and a plug having a sealing assembly. The cage can be fixed within the regulator body such that the cage does not move within the regulator body. More specifically, the cage can be received by a seat of the regulator such that a central opening of the cage is aligned with an orifice of the regulator body. For example, a central cage axis of the orifice can coincide with a regulator axis defined by the central opening of the cage.

[0042] Continuing, the plug can be movably received within the central opening of the cage to move relative to both the cage and the seat. For example, the plug can move along a range of travel along the cage axis toward or away from the seat to control the flow of fluid through at least a portion of the plurality of cage holes formed in the cage. More specifically, the plug can move between a closed configuration in which fluid is prevented from flowing from the inlet to the outlet through the cage and an open configuration in which fluid is allowed to flow from the inlet to the outlet via at least a portion of the plurality of cage holes. An actuator (e.g., a diaphragm) coupled to or disposed within the regulator can cause the plug to move.

[0043] In the fully closed configuration, the plug can sealingly contact the seat to create a full seal between a sealing surface of the plug and the seat. In this closed configuration, the sealing assembly can be disposed between the seat and all of the plurality of cage holes. Further, the sealing assembly can be in sealing contact with an inner surface of the cage to create a second seal that can also prevent fluid flow through the plurality of cage holes. Thus, the inner assembly can remain in the closed configuration even if the plug moves a small distance from the seat surface to fully or partially break the seal between the seat surface and the plug so long as the plug continues to prevent flow via the seal with the cage.

[0044] In the open configuration, the plug can be disposed away from the seat (i.e., axially displaced from the seat along a prescribed range of travel) such that at least a portion of the plurality of cage holes are exposed for flow through the seat. In this regard, in the open configuration, the plug can be generally oriented such that at least a portion of one or more of the cage holes are disposed between the seat and the sealing assembly of the plug to be exposed to flow through the regulator, where the exposed portion of the one or more cage holes defines a flow area through which fluid can generally flow from the inlet to the outlet of the regulator as a whole. Correspondingly, as the plug is further displaced away from the seat, the flow area generally increases depending on the configuration of the holes to allow fluid to pass through the regulator at a greater flow rate.

[0045] In some cases, the sealing assembly can selectively contact the inner surface of the cage to create a seal that can reduce blow-by (i.e., flow of fluid between the sealing assembly and the inner surface of the cage). In this way, for example, fluid flow through the inner member assembly can be better controlled, which can help the inner member assembly achieve a high turndown. In other words, because the sealing assembly can sealingly contact the inner surface of the cage, the sealing assembly can reduce (e.g., eliminate) any voids of undesired flow between the plug and the cage. This can generally prevent fluid from passing between the plug and the cage such that the plug assembly and the seat generally only allow fluid flow through the exposed portion of the cage holes of the cage. However, in some cases, the sealing assembly can not contact the inner surface of the cage (e.g., over a portion of the range of travel of the plug), which can result in blow-by and thus a higher flow rate of fluid through the inner member assembly.

[0046] The sealing assembly can be configured to sealingly contact the inner surface of the cage as the plug is moved relative to the cage depending on the position of the plug relative to the seat. More specifically, the outer surface of the sealing assembly can have a dimension (e.g., a diameter) that is greater than the dimension of the plug body. In this way, for example, the radially outer surface of the sealing assembly can contact the radially inner surface of the cage to establish a full or partial seal. In some cases, the sealing assembly can be or can include an elastomeric member, and the contact between the outer surface of the sealing assembly and the inner surface of the cage can correspondingly radially compress the sealing assembly into the groove.

[0047] In some examples, the plug can include a plug body (e.g., a cylindrical plug body) defining a circumferential outer groove and a sealing assembly retained within the groove. The plug body can be shaped to be movably received within the cage such that the plug body does not contact the inner surface of the cage. The groove can be configured to receive the sealing assembly such that the sealing assembly can be radially displaced within the groove.

[0048] In some examples, the seal assembly can include an outer ring and at least one resilient member. The outer ring can have an outer diameter that is greater than a diameter of at least a portion of the inner surface of the cage and an inner diameter that is less than a diameter of the plug body. In this manner, for example, the outer ring can be held within the groove and extend past the outer circumference of the plug to contact the inner surface of the cage at the outer ring surface and thereby provide a circumferential seal.

[0049] In some cases, the outer ring can enclose the at least one resilient member within a groove on the plug assembly such that the at least one resilient member can bias the outer ring radially outward from the groove. For example, when the outer surface of the outer ring contacts the inner surface of the cage, the contact can force (e.g., compress) the outer ring to move radially into the groove. This movement of the outer ring can cause the at least one resilient member to compress within the groove. In turn, the one or more resilient members can provide an opposing force to ensure that the outer ring maintains proper sealing contact with the inner surface of the cage. In some cases, by so ensuring that the outer surface of the outer ring maintains proper contact with the inner surface of the cage, a full or partial seal can be properly provided even in the event of a change in the size (e.g., diameter) of the inner surface of the cage. However, in some cases, the outer ring and resilient member can fully decompress (as relevant) when the plug is moved along a range of travel to a portion of the inner diameter of the cage that is larger than the outer diameter of the outer surface of the outer ring. Correspondingly, in certain cases, the outer surface of the ring can not form a seal with the cage even at the furthest distance of extension out of the groove depending on the local size of the cage.

[0050] As discussed generally above, the radially outward bias of the seal assembly can help ensure that a proper seal is provided between the plug assembly and the cage and correspondingly improve the high adjustment operation of the regulator. Similarly, the variation in the local size of the cage can allow the seal assembly on the plug to move along selected portions of the range of travel with little interference from the cage. Thus, for example, relatively precise control can be achieved at low flow rates and in combination with relatively low wear operation at high flow rates.

[0051] In some examples, the transition region within the cage can help ensure a relatively smooth and low wear transition between operation with contact between the seal assembly on the plug and the cage and operation without contact between the seal assembly and the cage. For example, in some examples, the cage can be an annular cage including a peripheral wall having a central opening extending between a first cage end and a second cage end. The central opening can be configured to movably receive the plug and can define an inner cage surface of the cage. The inner cage surface can further define a first seal portion adjacent the first cage end and a gap portion disposed distally from and downstream of the first cage end such that the first seal portion is positioned between the first cage end and the gap portion.

[0052] Continuing, the diameter of the first sealing portion can be less than the diameter of the gap portion, and a transition portion can be disposed between the first sealing portion and the gap portion. The transition portion can define a tapered region of the cage inner surface having a variable diameter, one end of which is adjacent to and continuous with the first sealing portion (e.g., having a diameter equal to that of the first sealing portion), and another end of which is adjacent to and continuous with the gap portion (e.g., having a diameter equal to that of the gap portion). The first sealing portion and the first tapered portion can be configured to contact a portion of the plug assembly (e.g., an outer surface of the sealing assembly) to allow the plug assembly to sealingly contact the cage inner surface depending on the position of the plug. The gap portion can be configured such that the peripheral sealing assembly of the plug is substantially disengaged from the cage inner surface (i.e., not in contact with the relevant surface, or 5% or less in contact with the relevant surface relative to the maximum potential contact area with the relevant surface on the relevant travel path) along the gap portion. Moreover, the continuous profile of the transition region can help ensure smooth movement of the plug assembly between the two modes of operation.

[0053] Generally, to facilitate proper regulation of flow through the regulator, the cage can include a plurality of cage holes defined in the peripheral wall of the cage. The plurality of cage holes can be configured to allow fluid flow through at least a portion of the plurality of cage holes to allow fluid flow through the regulator. In particular, depending on the position of the plug assembly, and more particularly the position of the sealing assembly of the plug assembly, a portion of the plurality of cage holes can be exposed to the flow path through the seat of the regulator (i.e., can extend between the sealing assembly of the plug and the seat of the regulator) to define a flow area through which fluid can flow through the cage. As the plug moves away from the seat, a greater portion of the plurality of cage holes can be exposed between the sealing assembly and the seat, thereby increasing the available flow area and enabling a higher flow rate through the regulator.

[0054] In some examples, the configuration of the plurality of cage holes can be varied to achieve desired flow characteristics. In other words, the plurality of cage holes varies in size, shape, orientation, number, etc. between different cages to achieve various desired increases in flow rate over a specified travel range of the plug. Thus, for example, the flow through the cage holes, and generally through the regulator, can be properly varied based on the current position of the plug relative to the seat by proper configuration of the cage holes.

[0055] In some examples, the cage can include a plurality of cage holes that can be configured as slots extending between the first cage end and the second cage end. The slots can be elongated slots that extend parallel to the cage axis, and can extend into or through at least one of the seal portion, the transition portion, or the gap portion of the cage. The slots can have equal or unequal lengths. Additionally, the slots can be equally or unequally spaced around the circumference (e.g., the circumference) of the perimeter wall of the cage. Furthermore, the slots can not extend all the way through the seal portion to allow the seal assembly of the plug to form a complete seal with the inner surface of the cage.

[0056] In some cases, the plurality of cage holes can be configured as a plurality of slots, where each slot defines a first portion that extends from the intersection between the transition portion and the gap portion of the cage toward the second cage end. The first portion can terminate before reaching the second cage end. For example, the first portion can extend partially into the second seal portion and terminate before the second cage end. Each of the first portions can have the same length (e.g., a length taken parallel to the cage axis), or they can have different lengths. Additionally, each of the first portions can have a width taken perpendicular to the length, which can be the same or different.

[0057] In some examples, the profile (e.g., the width in the circumferential direction) of a particular cage hole can vary in the axial direction, such that particular desired flow characteristics can be obtained. In some examples, some adjacent cage holes can have different lengths, which can result in only a subset of the cage holes being available for flow (or having a certain flow rate) in the initial movement of the plug assembly. For example, the axial length of some portions of the slots or other cage openings can vary, and thereby can exhibit different lengths of axial extension into the low flow (or other) portions of the cage.

[0058] As another example, some portions of a set of cage holes can be configured with a necked-down portion of reduced width relative to other portions of the cage holes. Because of the smaller width of the narrower portion, the available flow area can increase at a slower rate when the plug passes along the narrower portion than when the plug passes along the other portions. In this way, for example, the narrower portion can define a low flow portion of the cage and a low flow portion of the range of travel of the plug, while the other portions can define a high flow portion of the cage and a high flow portion of the range of travel of the plug.

[0059] In some examples, the plurality of cage holes can be configured as a plurality of holes that can be configured in staggered rows of different lengths. Additionally, the diameter of the holes can vary. In other examples, the plurality of cage holes can be configured (e.g., shaped) to achieve other desired flow characteristics, such as a fast opening, linear, or equal percentage flow configuration.

[0060] Figure 1 An example configuration of a regulator 100 is depicted upon which aspects of the present disclosure can be practiced. As shown, the regulator 100 can be configured to function as a back pressure regulator or a pressure reducing regulator (depending on the configuration of the associated pilot (not shown)) to control the distribution of fluid (e.g., natural gas) in a distribution system. However, other types of regulators can be considered for other examples. Moreover, while some of the discussion below can be presented in the context of a pressure reducing regulator, some examples of the disclosed technology can similarly be used in the context of a back pressure regulator.

[0061] In the illustrated example, the regulator 100 includes a housing 104 and an inner assembly 106 disposed within the housing 104 to help control the flow of fluid through the regulator 100. In particular, the inner assembly 106 can be movable between a closed configuration in which the inner assembly 106 prevents fluid flow through the regulator 100 and an open configuration in which fluid is allowed to flow through the regulator 100 via the inner assembly 106.

[0062] The housing 104 includes a cap 108 and a regulator body 110. The cap 108 is coupled to the regulator body 110 by a plurality of fasteners (e.g., threaded bolts) or other known coupling methods known in the art. The regulator body 110 includes an inlet 114 defining an inlet opening 116 and an outlet 118 defining an outlet opening 120. As shown, the inlet opening 116 and the outlet opening 120 are oriented such that an inlet axis 122 defined by the inlet opening 116 and an outlet axis 124 defined by the outlet opening 120 coincide with one another. However, other configurations are also contemplated, including configurations in which the inlet axis and the outlet axis can not be parallel or can not be coplanar.

[0063] The regulator body 110 also encloses an orifice 126 formed within the regulator body 110 such that a flow path 128 (see Figures 4-7 ) extends through the orifice 126 to connect the inlet 114 (i.e., an upstream end of the flow path 128) with the outlet 118 (i.e., a downstream end of the flow path 128). For example, the pressure of the fluid in the inlet 114 can be higher than the pressure of the fluid in the outlet 118 (e.g., as indicated by the bold and thin arrows, respectively, in Figures 4-7 ). As such, the relatively high pressure fluid in the inlet 114 will reduce in pressure as it passes through the orifice 126 to become a low pressure fluid in the outlet 118.

[0064] Orifice 126 can be a circular bore defining an adjuster axis 130. As shown, adjuster axis 130 is perpendicular to both inlet axis 122 and outlet axis 124; however, adjuster axis 130 can be angled relative to inlet axis 122 and / or outlet axis 124 in other ways. Surrounding orifice 126 and adjacent inlet 114, adjuster body 110 further includes an annular seat 132 having a seating surface 134 configured to receive at least a portion of inner member assembly 106. As shown, annular seat 132 is a separate structure configured to be received within adjuster body 110, although in some examples annular seat 132 can be integrally formed within adjuster body 110.

[0065] Inner member assembly 106 includes a cage 136 configured to movably receive a plug 138 of plug assembly 178 and disposed along flow path 128. Accordingly, cage 136 generally surrounds flow path at orifice 126 to separate inlet 114 from outlet 118 along flow path 128. Correspondingly, the particular configuration of inner member assembly 106 can assist in regulating the flow of fluid through regulator 100 along flow path 128. More particularly, as will be described in greater detail below, relative motion between cage 136 and plug 138 can assist in characterizing fluid flow through the regulator at a given inlet pressure (or other flow condition).

[0066] As Figure 2 and Figure 3 shown, in particular, cage 136 includes an annular body having a peripheral wall 140 defining a cage central opening 142 extending between a first cage end 144 and a second cage end 146. As shown, each of first cage end 144 and second cage end 146 includes a cage flange 148 extending radially from peripheral wall 140. However, in some examples, a cage flange can be absent. Additionally, cage 136 includes a plurality of cage apertures 150 formed in and extending through peripheral wall 140 to allow fluid to pass through cage 136 for flow through regulator 100 along flow path 128 depending on the position of plug 138 (see Figure 1 ), as discussed further below. Moreover, cage central opening 142 defines a cage axis 152 and is configured to movably receive plug 138 such that plug 138 can be axially moved relative to cage 136 along cage axis 152.

[0067] More particularly, cage central opening 142 defines a cage inner surface 154 (see Figure 3 ), which is configured to be engaged by plug 138 (see Figure 1) to control the flow of fluid through the cage 136, as discussed further below. In this regard, for example, the cage inner surface 154 defines a sealing portion 156 proximate the first cage end 144 and a gap portion 158 disposed distal to the first cage end 144 and downstream of the first cage end 144 beyond the sealing portion 156. In other words, the sealing portion 156 can be closer to the first cage end 144 than the gap portion 158, and the gap portion 158 can be closer to the second cage end 146 than the sealing portion 156. In some cases, the gap portion 158 can extend to the second cage end 146, although other configurations are possible, including those discussed below. Additionally, one or more of the cage apertures 150 can extend into both the sealing portion 156 and the gap portion 158, although other configurations are possible.

[0068] The sealing portion 156 can be generally configured such that a sealing assembly of the plug 138 (also discussed below) can seat on the cage inner surface 154 of the peripheral wall 140. Thus, for example, the plug assembly can seal completely or partially around the circumference of the sealing portion 156 to control the flow of fluid through the cage 136. More specifically, the sealing portion 156 can have a diameter that is less than the maximum diameter of the plug assembly to ensure sealing contact between the plug assembly and the sealing portion 156.

[0069] The gap portion 158 can be disposed beyond the sealing portion 156 such that the gap portion 158 is closer to the second cage end 146 than the sealing portion 156. In the illustrated example, the gap portion 158 has a diameter that is greater than the diameter of the sealing portion 156 and the plug assembly such that the plug assembly is substantially disengaged from the cage inner surface 154 along the gap portion 158 (i.e., not in contact with the relevant surface, or 5% or less contact with the relevant surface relative to the maximum potential contact area with the relevant surface in the relevant travel path), as discussed further below.

[0070] As also discussed further below, the gap portion can allow for increased flow of fluid through the cage for some positions of the plug assembly, as well as reduced wear of the plug assembly and improved overall operating efficiency of the regulator. However, in certain examples, the gap portion can not be provided, or the sealing portion of the cage can extend over a greater axial portion of the cage in other ways than illustrated for the sealing portion 156 such that the sealing assembly of the plug assembly can seal along a greater axial length of the cage inner surface.

[0071] In some cases, including cases where the cage includes a larger diameter gap portion and a smaller diameter seal portion, a transition portion can be provided. For example, the cage inner surface 154 can further define a transition portion 160 that extends between and connects the seal portion 156 and the gap portion 158. By providing a relatively smooth profile between the seal portion 158 and the transition portion 160, the transition portion 160 can help provide a smooth transition for the seal assembly as the plug assembly moves between the gap portion 158 and the seal portion 156, including as discussed further below. Correspondingly, for example, the plug 138 can more easily move between the gap portion 158 and the seal portion 156 while reducing wear on the seal assembly.

[0072] In the illustrated example, the transition portion 160 provides a region having a varying diameter. In particular, at a location where the transition portion 160 connects with the seal portion 156, the transition portion 160 can have a diameter equal to that of the seal portion 156, and at a location where the transition portion 160 connects with the gap portion 158, the transition portion can have a diameter equal to that of the gap portion 158. In different examples, the diameter of the transition portion can vary linearly or non-linearly along the axial length to provide a smooth transition between the seal portion and the gap portion. As illustrated, the transition portion 160 is tapered such that the diameter varies linearly along the length of the transition portion 160, although other configurations are possible.

[0073] Referring again to Figure 1 In some cases, the inner assembly can further include a cage retainer to help ensure that the cage does not move relative to the regulator body or seat. In particular, in the illustrated example, the cage retainer 162 is formed as an annular body that defines a retainer opening 164 that extends between a first retainer end configured to connect with the cage 136 and a second retainer end configured to connect with the housing 104. The cage retainer 162 extends between the housing 104 and the second cage end 146 such that, when the cap 108 is secured to the regulator body 110, the cage retainer 162 can be pushed downward by the cap 108 to apply a force to the cage 136 that can secure the cage 136 against the seat 132. Additionally, the retainer central opening 164 can be concentric with the cage central opening 142 and can be configured to movably receive the plug 138.

[0074] The plug 138 includes a plug body 174 and supports a (peripheral) seal assembly 176 (i.e., a peripheral seal element), which is also contained in a plug assembly 178. The plug body 174 can be a substantially cylindrical body having an upstream end and a downstream end (i.e., a lower end and an upper end, as shown) and can include a plug cavity defined in the upstream end, although other configurations are possible. As also noted above, the plug 138 is configured to be movably received within the cage central opening 142 and to move relative to the cage 136 and seat 132 to control the flow of fluid along the flow path 128. (As discussed herein, the "upstream" and "downstream" portions of a plug's cage are generally identified based on the direction of fluid flow at the corresponding valve seat cage. Thus, for example, the upstream end of the plug 138 is oriented toward the top of the plug 138 in the illustrated orientation, as fluid flows generally in an upward direction through the seat 132.) Figure 1

[0075] To facilitate movement of the plug 138, the plug 138 can be coupled with a diaphragm 188 positioned between the regulator body 110 and the cap 108. A spring (not shown) can also be provided to help establish the operating set pressure of the regulator 100. Generally, the diaphragm 188 can move the plug 138 relative to the cage 136 in accordance with the fluid pressure at the inlet 114 to control the flow of fluid along the flow path 128. More specifically, the diaphragm 188 can move the plug 138 relative to the cage 136 and seat 132 over a range of travel to vary the flow area for flow through the seat 132 (e.g., as discussed below) such that fluid is allowed to flow through the cage 136 to appropriately meet downstream demand. In other examples, other known mechanisms can similarly be employed to regulate the movement of the plug.

[0076] During operation of the regulator 100, as downstream demand increases, the fluid pressure at the outlet 118 can decrease, causing the diaphragm 188 to move upwardly toward the cap 108 and thereby move the plug 138 upwardly away from the seat 132. As described in further detail below, this movement can expose a greater portion of the plurality of cage holes 150 of the cage 136 to increase the available flow area and thereby achieve a higher flow rate through the regulator 100. Conversely, as downstream demand decreases, the fluid pressure within the outlet 118 can increase, causing the diaphragm 188 to move downwardly away from the cap 108 and move the plug 138 downwardly toward the seat 132. As also described in further detail below, this movement can block a greater portion of the plurality of cage holes 150 of the cage 136 to decrease the available flow area and thereby decrease the flow rate through the regulator 100.

[0077] ​To better control the flow of fluid through the cage 136, including via reduction of cross- flow (i.e., fluid undesirably passing between the plug 138 and the cage 136), the seal assembly 176 of the plug 138 can be configured to partially or fully seal against the cage inner surface 154 depending on the position of the plug 138. More specifically, for the illustrated example, the seal assembly 176 can be configured to selectively and sealingly contact the cage inner surface 154 only at the sealing portion 156 and the transition portion 160, although other configurations are possible.

[0078] Generally speaking, here, the seal assembly can include a seal member that can be biased (e.g., via its own compressibility or via a separate biasing member) into sealing engagement with an adjacent region on the inner surface of the cage. Thus, for example, cross-flow can be largely prevented within at least a portion of the travel range of the plug relative to the cage, and performance correspondingly improved, particularly at low flow rates.

[0079] In the illustrated example, and with particular reference to Figure 4 , the plug 138 includes a seal groove 190. As shown, the seal groove 190 is a peripheral circumferential groove, although other shapes and configurations of the seal groove are also contemplated. That is, the seal groove 190 is an external groove formed in the radial outer periphery of the plug body 174 and positioned to be located near the lower end of the plug 138. In this way, for example, when the plug 138 is in the fully closed configuration, the seal assembly 176 can be positioned adjacent the sealing portion 156 of the cage 136, as Figure 4 shown. In some cases, the seal groove 190 can be configured to allow radial movement of the seal assembly 176 within the seal groove 190, such that the seal assembly 176 can be easily moved to sealingly contact the cage inner surface 154, but also be appropriately compressed, including so as to avoid excessive wear.

[0080] Generally, configuring a sealing assembly to provide a peripheral seal can be useful. For example, a sealing assembly 176 may completely surround the outer periphery of a plug body 174 to provide a seal between a plug assembly 178 and the inner surface 154 of a cage. In different examples, different peripheral sealing elements and biasing elements (as appropriate) may be used. For example, as shown, a sealing assembly 176 may include a peripheral sealing element configured as an outer ring 192 that surrounds and encloses two resilient members 194 (e.g., configured as rubber O-rings) within a sealing recess 190. More specifically, in the example shown, each of the resilient members 194 is held within a separate sub-recesses 190A, 190B defined in the main sealing recess 190. This arrangement, among other advantages, helps improve the retention of the sealing assembly 176. However, other configurations of the sealing assembly are also conceivable. For example, the sealing assembly may include more or fewer resilient members, and the resilient members may also be configured as other types of resilient members, including linear springs or wave springs. In some cases, the sealing assembly may include a single sealing element (e.g., a single outer ring similar to outer ring 192 or otherwise configured). In some cases, the sealing assembly may include a single resilient member (e.g., a single O-ring similar to one of resilient members 194). In some cases, the peripheral groove on the plug assembly may include only a single channel (e.g., without multiple sub-grooves), which may hold one or more resilient members, one or more sealing elements, or a combination of one or more resilient members and one or more sealing elements.

[0081] In some cases, a sealing assembly may include a sealing member (e.g., a spring-driven seal) but may not include a separate biasing member. In some cases, more than one sealing assembly may be used, including configurations in which each sealing assembly is disposed in a separate corresponding sealing recess. In different examples, different materials may be used for the sealing member. For example, the outer ring 192 may be made of an elastic material (e.g., Delrin® plastic or other polymers (Delrin is a registered trademark of DuPont deNemours, Inc. in the U.S. or other jurisdictions)).

[0082] Continue to refer to Figure 4 The outer ring 192 defines an outer ring surface 196, which is configured to sealably contact the inner surface 154 of the cage according to the position of the plug 138. More specifically, the diameter of the outer ring surface 196 may be larger than the diameter of the sealing portion 156 and smaller than the diameter of the gap portion 158. In this way, for example, the sealing region 198 defined by the outer ring surface 196 is in a fully closed configuration when the plug assembly 178 is in (see...) Figure 4 When the plug assembly 178 is in the corresponding open configuration (see example...), it can contact the cage 136 around the entire circumference of the sealing portion 156, and when the plug assembly 178 is in the corresponding open configuration (see example...).Figure 9 Further, the outer ring surface 196 can at least partially contact the cage inner surface 154 along the transition portion 160 (see Figure 7 ), which can allow the outer ring surface 196 to at least partially seal against the transition portion 160 of the cage inner surface 154. Additionally, the inner diameter of the outer ring 192 can be smaller than the outer diameter of the plug body 174, such that the outer ring 192 is held within the sealing groove 190.

[0083] With continued reference to Figure 1 and Figure 4 the regulator 100 is shown with the inner assembly 106 in a first, closed configuration in which fluid is prevented from flowing through the regulator 100. In the first, closed configuration, which is a fully closed configuration, there can be no downstream demand for fluid and the plug 138 is in a first position (i.e., a first axial position) in which the lower end of the plug 138 is in sealing contact with the seating surface 134 of the seat 132. The contact between the lower end of the plug 138 and the seat 132 can establish a primary seal that prevents fluid from passing through the seat 132 and flowing through the plurality of cage holes 150 of the cage 136.

[0084] Further, in the first, closed configuration, the seal assembly 176 is also in full sealing engagement with the cage 136 to provide a secondary seal. The secondary seal can further enhance the ability of the inner assembly 106 to prevent fluid flow through the regulator 100, including during small movements of the plug assembly 178 relative to the seat 132. More specifically, the outer ring surface 196 of the outer ring 192 can be biased into sealing contact with the cage inner surface 154 along the entire circumference of the sealing portion 156 between the first cage end 144 and the plurality of cage holes 150. In other words, at least a portion of the outer ring 192 is not axially aligned with any of the plurality of cage holes 150 (i.e., is not along the same radial line relative to the axis of opening / closing movement of the plug 138), such that no portion of the cage holes 150 is exposed as part of a flow path through the regulator 100.

[0085] In the illustrated example, the sealing contact between the outer ring 192 and the cage inner surface 154 is maintained due to the sealing portion 156 of the cage 136 having a smaller diameter than the resting diameter of the outer ring 192 at the outer ring surface 196 and due to the radial outward bias provided by the resilient members 194 on the outer ring 192. As a result, the sealing portion 156 of the cage inner surface 154 can radially compress (i.e., radially inward toward the plug body 174) the outer ring 192 toward (e.g., into) the sealing groove 190. In doing so, the outer ring 192 can then compress each of the resilient members 194, which can provide a counter force that biases the outer ring 192 against the sealing portion 156 to ensure sealing contact between the outer ring and the sealing portion. In this manner, for example, the seal assembly 176 blocks all of the plurality of cage holes 150 such that fluid cannot flow through the cage holes of the plurality of cages 136 to the inlet 114. In some cases, the outer ring 192 and the resilient members 194 can be fully compressed when the seal assembly 176 is disposed within the sealing portion 156. In other words, the seal assembly 176 can be fully compressed when in radial alignment with the sealing portion 156.

[0086] As noted above, in some cases, when the plug assembly is fully closed against the seat and when the plug assembly is lifted away from the seat by a relatively small amount, the biased seal assembly can help maintain a seal to prevent flow through the regulator. Turning back to the example of FIG. 1, for example, the regulator 100 is shown with the inner assembly 106 in a second closed configuration in which the plug 138 has been moved along a first range of travel in the opening direction (i.e., upward, as shown) to a second position (i.e., a second axial position) to displace the plug 138 away from the seat 132. In this position, the inner assembly 106 is still in a closed configuration, and fluid is prevented from flowing along the flow path 128 due to the seal assembly 176 continuing to form a full seal along the entire circumference of the sealing portion 156. Figure 3

[0087] ​More specifically, the sealing region 198 (of the outer ring 192 of the seal assembly 176) remains in sealing engagement along the entire circumference of the sealing portion 156, even if the lower end of the plug 138 is not in contact with the seat 132. Further, the upstream edge (i.e., the bottom edge, as shown) of the sealing region 198 of the outer ring 192 is not axially aligned with any of the plurality of cage holes 150, such that the sealing engagement with the sealing portion 156 of the cage 136 extends between the plurality of cage holes 150 and the seat 132. As a result, all of the plurality of cage holes 150 are blocked, and thus there is no flow region through which fluid can pass from the inlet 114 to the outlet 118 along the flow path 128. However, in other examples, other configurations are possible. For example, as also discussed below, in some cases, different configurations of cage holes are also possible, and correspondingly, some configurations can result in the flow path through a portion of one or more cage holes being opened immediately upon lifting the plug assembly away from the main seat of the regulator.

[0088] Turning to Figure 6 and Figure 7 In response to an increased downstream demand for fluid, the plug assembly 178 can be further opened in the opening direction within a second range of travel to place the plug 138 in a third position (i.e., a third axial position). (The positions of the plug 138 are not limited to the discrete example positions shown herein during actual operation. Those skilled in the art will recognize that the flow effects can vary accordingly, as generally indicated as discussed herein). In the third position, the plug 138 is displaced even further away from the seat 132, such that the inner member assembly 106 is in a first open configuration (which is not necessarily the initial open configuration that allows flow through the cage 136). In the first open configuration, the outer ring 192 of the seal assembly 176 can be in partial sealing contact along either the sealing portion 156 or the transition portion 160 of the cage inner surface 154, such that a portion of the plurality of cage holes 150 is positioned between the seal assembly 176 and the seat 132. In particular, while an upstream section of the outer ring surface 196 of the outer ring 192 can remain axially aligned with and in contact with the sealing portion 156 to provide a partial seal, an upstream portion of one or more of these cage holes 150 is positioned between the upstream edge of the outer ring 192 and the seat 132, such that the exposed portion of the hole 150 provides a flow region 186a. In other words, the upstream end of the outer ring 192 is axially aligned with the plurality of cage holes 150, such that a portion of the plurality of cage holes 150 extends between the seal assembly 176 and the first (upstream) end of the cage 136 to provide a relatively limited flow region 186a through which fluid can travel to proceed along the flow path 128 through the regulator 100.

[0089] In contrast to conventional arrangements that typically provide a gap between the plug assembly and the cage, the seal assembly 176 can be in at least partial sealing contact with the cage 136 when the plug assembly 178 is in the first, open configuration, such that fluid can generally pass only through the unobstructed portions of the plurality of cage holes 150 (i.e., the available flow area 186a), and not between the plug assembly and the cage inner surface 154. Also as noted above, for example, within the sealing portion 156 (and within a portion of the transition portion 160), the cage inner surface 154 has a smaller diameter than the outer ring surface 196 of the outer ring 192. Thus, particularly under the bias of the resilient member 194, the outer ring 192 can seal against the portion of the cage inner surface 154 that extends between individual ones of the plurality of cage holes 150. In this manner, the available flow area 186 can be better controlled than in conventional systems, which can allow the inner member assembly 106 to better control fluid flow at lower flow rates in situations where the plug 138 is operating in close proximity to the seat 132.

[0090] With particular regard to the transition portion 160, as the plug assembly 178 continues to move in the open direction (i.e., upward, as shown), an upstream portion of the outer ring surface 196 can initially remain in contact with the cage inner surface 154 despite the increasing diameter of the cage inner surface 154 due to the radially outward bias provided by the resilient member 194. In other words, in the transition portion 160, the outer ring 192 and the resilient member 194 can only partially decompress, as the contact between the outer ring surface 196 and the cage inner surface 154 can inhibit further outward movement of the outer ring 192. Thus, the seal assembly 176 can be partially compressed within a portion of the transition portion 160. Further, appropriate configuration of the geometry of the transition portion (e.g., the linear transition geometry as shown for the transition portion 160) can provide an additional configurable parameter to implement appropriate flow characteristics for high adjustment operations.

[0091] In some cases, with sufficient open movement of the plug assembly, a gap can eventually be achieved between the seal assembly and the cage inner surface, as with respect to Figure 8 and Figure 9 As further discussed, in contrast, as the plug assembly moves in the closed direction, the transition portion of the cage can help ensure relatively low-wear compression of the seal assembly contained in the plug assembly. For example, as the plug assembly 178 moves in the closed direction (i.e., downward, as shown), the gradual transition geometry provided by the transition portion 160 can ensure that the seal assembly 176 is compressed to form an appropriate seal with the cage inner surface 154 within the sealing portion 156 without necessarily including hard edges or other high-wear contact points that can cause premature degradation of the outer ring 192.

[0092] Turning to Figure 8 and Figure 9In response to increased downstream fluid demand, the plug assembly 178 can be further opened in the third stroke range to place the plug 138 in a position greater than the second position (see...). Figure 6 and Figure 7 The third position is further away from the seat 132. With the plug assembly 178 in the third position as shown, the inner component assembly 106 is in a second open configuration. In the second open configuration, the outer ring 192 of the sealing assembly 176 is axially aligned with the plurality of cage holes 150 within the gap portion 158 of the inner surface 154 of the cage. In particular, because the plug 138 has been positioned further away from the seat 132, a larger portion of the plurality of cage holes 150 extends between the outer ring 192 of the sealing assembly 176 and the first cage end 144. Therefore, a larger portion of the plurality of cage holes 150 is not blocked, thus providing an increased usable flow area 186b, which allows for a higher flow rate of fluid along the flow path 128. More specifically, considering the shape and orientation of the cage holes 150, moving the plug 138 from the second position to the third position causes a non-linear increase in the movement of the flow area 186 relative to the plug 138. However, in other cases, the increase in the flow region can be linear, or it can vary in a manner different from that shown for regulator 100.

[0093] Because the diameter of the gap portion 158 is larger than the diameter of the outer ring surface 196 of the outer ring 192, the outer ring 192 may not seal or contact the inner cage surface 154 within the gap portion 158. For example, within the gap portion 158, the sealing assembly 176 is completely uncompressed (i.e., each of the elastic member 194 and the outer ring 192 is completely uncompressed), allowing a gap 200 to exist between the outer ring surface 196 of the outer ring 192 and the inner cage surface 154. Because the outer ring 192 may not contact the gap portion 158 of the inner cage surface 154, wear on the sealing assembly 176 can be reduced, which can extend the service life of the regulator 100. Additionally, due to the gap 200 between the inner cage surface 154 and the outer ring surface 196 of the outer ring 192, leakage may occur, potentially increasing the effective flow area 186 to allow for increased flow rates. For example, some fluid from the inlet 114 may pass through the gap 200 and enter the inlet 114 via blocked portions of the multiple cage orifices 150.

[0094] As downstream demand increases, the plug assembly 178 can continue to move away from the seat 132 within the fourth stroke range to position the plug 138 in a position greater than the third position (see...). Figure 8 and 9In a fourth position, further away from the seat 132, the available flow area can be larger than the second flow area 186b of the plug assembly 178 and can be retained in the gap portion 158. Therefore, this further movement of the plug assembly 178 into the gap portion 158 may also allow leakage, as described above.

[0095] It should be understood that as downstream demand for fluid decreases, plug 138 can move in the opposite closing direction to reduce the available flow area 186 and thus reduce the flow rate of fluid 102. Therefore, as demand decreases, plug 138 can move within its stroke range to move plug 138 toward seat 132. For example, if plug 138 is positioned within gap portion 158 (see example...) Figures 6-7 If the plug 138 can be moved into either the transition portion 160 or the sealing portion 156, the fluid flow rate can be reduced (see example). Figures 4-5 More specifically, as the plug moves into the transition portion 160, the outer annular surface 196 of the outer ring 192 contacts the inner surface 154 of the cage, which radially compresses the outer ring 192 into the sealing groove 190. As the plug 138 continues to move in the closing direction, the outer ring 192 continues to compress through the transition portion 160 until it is fully compressed at the sealing portion. Further, depending on downstream requirements, the plug 138 can be moved to a closed configuration (see, for example...). Figures 1-3 ).

[0096] Refer again Figure 2 and Figure 3 The diagram shows multiple cages 150 in more detail. While the illustrated configuration of the cages 150 may provide specific benefits in some cases, including by allowing relatively precise control of the flow rate during the initial opening movement of the plug assembly 178, in other examples, other shapes, numbers, sizes, spacing, or orientations of the cages may be varied to provide different flow characteristics (i.e., different relationships between the distance the plug assembly is displaced from the seat and the corresponding flow area provided or the fluid velocity allowed for a given pressure drop).

[0097] As shown in the figure, a plurality of cage openings 150 are configured as a plurality of slots 202 of different lengths, the slots being equidistantly spaced around the circumference of the peripheral wall 140 and extending along an elongation direction parallel to the cage axis 152. Each of the slots 202 includes a first portion 204, the first portion extending from the intersection of the transition portion 160 and the gap portion 158 (see Figure 150). Figure 3 It extends toward the second cage end 146 (i.e., upward, as shown). Additionally, some of the slots 202 include a second portion 206, which extends from the intersection between the transition portion 160 and the gap portion 158 (see...). Figure 3extend toward the first cage end 144 (i.e., downward, as shown). In other words, the second portions 206 can be continuous with and relatively extend opposite the respective first portions 204. Further, for the illustrated mounting orientation, the second portions 206 form the upstream ends of the slots 202 and the first portions 204 form the downstream ends of the slots 202. However, in other examples, the first portions 204 and the second portions 206 can not be continuous, including such that the second portions 206 are the upstream slots and the first portions are separate downstream slots. Figures 4 to 9

[0098] Similarly, in some cases, the transitions between different portions of the slots (e.g., portions having different circumferential widths or other flow profiles) can be located at different locations than illustrated for the slots 202. For example, in other configurations, each of the first portions 204 can also begin from any location within any of the sealing portions 156, the transition portions 160, or the gap portions 158, such that they can extend to any location between the first cage end 144 and the second cage end 146. Likewise, while each of the slots 202 is illustrated as terminating prior to reaching the cage ends 144, 146, with each of the first portions 204 having equal axial lengths and equal circumferential widths, in other examples, the first portions can have different lengths and different widths.

[0099] Generally speaking, the flow profile (i.e., the geometric profile defining the flow area of a given location of the plug assembly) of different portions of a particular cage hole can be configured to vary in a number of ways in order to provide different flow characteristics at different lift heights of the plug assembly and, in turn, provide different overall flow characteristics for a particular regulator. In the illustrated example, each of the second portions 206 can be configured as a necked-down portion having a width that is less than the width of the associated first portion 204. Generally speaking, the relative widths of each of the first portions 204 and the second portions 206 can vary in different examples to achieve particular desired flow characteristics. For example, the ratio of the width of the second portion 206 to the width of the first portion 204 can range from 0.1 to 0.9. In some cases, providing a reduced portion of the width of the cage hole as narrow as possible, within the limits of manufacturability, can be advantageous.

[0100] In some cases, portions of adjacent (or other) cage holes can extend different axial lengths, including potentially resulting in the cage holes extending into the transition, sealing, or gap portions of the cage in different amounts. For example, with particular reference to the illustrated example, the first portion 204 of the first cage hole 102 can extend a greater axial length than the first portion 204 of the second cage hole 104. In other words, the first portion 204 of the first cage hole 102 can extend further into the transition portion 160 of the cage 150 than the first portion 204 of the second cage hole 104. In some cases, the first portion 204 of the first cage hole 102 can extend into the transition portion 160 of the cage 150 by an amount that is greater than the axial length of the second portion 206 of the first cage hole 102. In other words, the first portion 204 of the first cage hole 102 can extend further into the transition portion 160 of the cage 150 than the second portion 206 of the first cage hole 102. Figure 3 ​From left to right, the first two slots do not include the second portion and do not extend into the sealing portion 156. However, starting from the third slot from the left, the length of the second portion 206 gradually increases towards the middle slot 202, and then gradually decreases again to the penultimate slot 202, where the second portion 206 extends into the sealing portion 156 by a correspondingly varying amount. Finally, the last two slots 202 on the right do not include the second portion, similar to the first two slots 202 as described above. In this way, for example, the cage 136 can provide particularly advantageous characteristics during the increase in adjustment. In particular, as the plug 138 moves away from the seat 132, the available flow area 186 can increase more gradually compared to the case where all of the plurality of slots 202 have the same length or all of the plurality of slots 202 have the same width. Furthermore, as described above, other configurations of the cage orifices in other examples can be varied as needed to provide other beneficial flow characteristics.

[0101] For further reference Figure 10 The flow characteristics of the regulator 100 are shown, which are determined in part by the configuration of the cage 150 and the plug assembly 178. Specifically, this is determined by the second portion 206 of the slot 202 (see...). Figure 2 and Figure 3 The relatively small flow regions provided by the flow characteristics can collectively define the low-flow portion 208 of the cage 136, wherein a corresponding low-flow portion 208' is present on the flow characteristic curve (see...). Figure 10 Conversely, the first part 204 of the slot 202 (see...) Figure 2 and Figure 3 The relatively large flow region provided by the flow characteristics can collectively define the high flow rate portion 210 of the cage 136, wherein the flow characteristic curve has a corresponding high flow rate portion 210' (see Figure 10 Correspondingly, the low-flow portions 208, 208' generally correspond to at least a portion of the transition portion 160 between the sealing assembly 176 and the cage 136 and the alignment of the sealing portion 156 (see, for example...). Figure 7 ), and the high-flow portions 210, 210' generally correspond to the alignment of the gap portion 158 between the sealing assembly 176 and the cage 136 (see, for example) Figure 9 Furthermore, due to the specific geometry of the cage 136, and especially the specific geometry of the slot 202, the flow characteristic curve of the regulator 100 defines an additional low-flow transition section 208'', in which the flow rate increases at an intermediate rate relative to the movement of the plug 138.

[0102] More specifically, for common reference Figures 1 to 10As the plug 138 moves away from the seat 132, fluid can first flow only through a portion of the second portions 206 of the plurality of slots 202, as reflected by portion 208' of the flow characteristic curve. As the plug 138 continues to move away from the seat 132, additional second portions 206 can become unobstructed to increase the available flow area 186, thereby increasing the flow rate of fluid through the cage 136, as reflected by the change in slope of the flow characteristic curve at the transition to portion 208''. In this manner, for example, if the second portions 206 all have the same length, the plug 138 can have to move over a longer range of travel to achieve the same increase in flow rate as compared to a desired flow rate. Correspondingly, relatively precise control can be achieved even for low flow rates. Further, by increasing the range of travel required to achieve a desired increase in flow rate, the plug 138 can be operated further away from the seat 132, which can improve flow stability at low flow rates by reducing the risk of the plug inadvertently contacting the seat 132 and cutting off flow. Additionally, the regulator 100 can be better responsive to small changes in demand at low flow rate scenarios.

[0103] Eventually, the plug 138 can move into a high flow portion 210, which corresponds to portion 210' of the flow characteristic curve. In the high flow portion 210, the wider width of the first portions 204 allows the flow rate to increase at a faster rate than in the low flow portion 208, as reflected by the increase in slope of the flow characteristic curve at portion 210'. In other words, for a given range of travel of the plug 138, the wider width of the first portions 204 results in a greater amount of increase in available flow area (i.e., at a faster rate) than the same range of travel within the low flow portion 208. In the case where the plug 138 is located in the gap portion 158, this increase in available flow area 186 can be further increased due to the extent of cross- flow allowed by the void 200 (see Figure 9 ) that allows some fluid to pass through the cage 136 via portions of the plurality of slots 202 that would otherwise be obstructed by the plug 138 if the plug 138 were aligned with the sealing portion 156.

[0104] As noted above, the shape and number of the plurality of cage apertures can vary in different examples to achieve desired flow characteristics. For example, Figure 11 Another example configuration of a cage 1136 is depicted in accordance with aspects of the present disclosure. The cage 1136 is generally similar to the cage 136 and includes a peripheral wall 1140 defining a cage central opening 1142 extending between a first cage end 1144 and a second cage end 1146, and defining a cage axis 1152. Additionally, the peripheral wall 1140 has a plurality of cage apertures 1150. However, the plurality of cage apertures 1150 are configured as a plurality of circular holes 1212 in a regular array.

[0105] Specifically, the holes 1212 are all circular in shape and are distributed in staggered axial rows extending parallel to the cage axis 1152. The length of each row varies, such that some rows extend closer to the first cage end 1144 than others. Furthermore, the size of the holes 1212 can vary. For example, a portion of these rows includes a larger hole 1214 located at the corresponding end of the row closest to the second cage end 1146. In this way, for example, cage 1136 can be configured to have a low-flow portion 1208 and a high-flow portion 1210, which can allow cage 1136 to provide improved adjustment similar to cage 136. For example, the low-flow portion 1208 can correspond to the upstream portion into which these rows extend by different amounts, and the high-flow portion 1210 can correspond to the downstream portion into which all these rows extend over the entire length, and the downstream portion also includes the larger hole 1214. In some cases, in addition to improved adjustment performance, using cage openings with a similar configuration to opening 1212 can also advantageously reduce noise during operation.

[0106] As also mentioned above, various other known cage configurations can be combined with the sealing arrangements disclosed herein to achieve other flow characteristics. For example, Figure 12 Cage 2136 is shown, having a known profile to provide rapid opening flow characteristics that allow for a rapid increase in flow rate over a small stroke range within the cage 2136. For example, cage 2136 can provide... Figure 15 The line 2216 reflects the flow characteristics. Generally, in order to provide this rapid opening flow characteristic, the cage 2136 may have a peripheral wall 2140, which includes a plurality of larger cage openings 2150 configured as squares or other shapes, which provide a significant increase in the flow area even within a short stroke range of the plug (e.g., plug 138).

[0107] As another example, Figure 13 A cage 3136 with a known profile is shown to provide linear flow characteristics. To provide linear flow characteristics, the cage 3136 has a peripheral wall 3140 with a plurality of cage openings 3150, which are configured (i.e., shaped) to provide a linear increase in flow rate relative to the stroke range of the plug, such as... Figure 15 As reflected in line 3216. As yet another example, Figure 14 Another cage 4136 is shown, which has a known profile to provide equal percentage flow characteristics. To provide equal percentage flow characteristics, cage 4136 has a peripheral wall 4140 with a plurality of cage orifices 4150, the orifices being configured such that the flow velocity increases exponentially with respect to the travel range of the plug, such as... Figure 15as reflected by line 4216.

[0108] While some cages can provide only a single flow characteristic, other cages can be configured to provide multiple flow characteristics depending on the mounting orientation of the cage. For example, some cages can be configured to be selectively mounted in opposite orientations (e.g., flipped upside down) to provide a second flow characteristic, which can be different or the same as the first flow characteristic. For example, Figure 16 An example cage 5136 is shown that can be used with regulator 100 or another regulator. Cage 5136 is configured to selectively provide a first flow characteristic in a first orientation (e.g., flow from bottom to top relative to the orientation shown) and a second flow characteristic in a second orientation (e.g., flow from top to bottom relative to the orientation shown).

[0109] In general, cage 5136 is similar to cage 136 and has a peripheral wall 5140 that defines a cage central opening 5142 extending between a first cage end 5144 and a second cage end 5146. Cage central opening 5142 defines a cage inner surface 5154 having a first sealing portion 5156 proximate first cage end 5144, a gap portion 5158 toward an axial center of cage 5136, and a first transition portion 5160 extending between and connecting the first sealing portion 5156 and the gap portion 5158.

[0110] However, cage inner surface 5154 also defines a second sealing portion 5218 proximate second cage end 5146 and a second transition portion 5220 extending between and connecting the second sealing portion 5218 and the gap portion 5158. Thus, gap portion 5158 is disposed between first sealing portion 5156 and second sealing portion 5218 such that cage 5136 can be selectively positioned within a regulator in either of the first and second orientations so that either of cage ends 5144, 5146 is an upstream end of regulator 5136. For example, cage 5136 can be oriented in the first orientation within regulator 100 such that first cage end 5144 is in contact with seat 132 (see Figure 1 ). Conversely, cage 5136 can be flipped upside down in the second orientation such that second cage end 5146 is in contact with seat 132. Second sealing portion 5218 is similar to first sealing portion 5144 and second transition portion 5220 is similar to first transition portion 5160 in the example shown, although other configurations are possible, including providing different overall flow characteristics depending on the mounting orientation of the associated cage.

[0111] As mentioned, cage 5136 can be configured according to the relevant cage openings, transition portions, gap portions or other features, particularly relative to the relevant sealing assembly (e.g., Figure 1 The configuration of the sealing assembly 176 provides different flow characteristics in each of the first and second orientations. For example... Figure 16 As shown, cage 5136 includes a plurality of cage openings 5150 formed as slots in peripheral wall 5140. Similar to the plurality of cage openings 150, each of the cage openings 5150 has a first wider portion 5204 and a second narrower portion 5206. However, for each of the slots 5202, the narrower portion 5206 has a substantially the same length. Therefore, the narrower portion 5206 extends from the wider portion 5204 into the sealing portion 5156 to provide a corresponding low flow area.

[0112] Due to the shape and orientation of the cage openings 5150, the cage 5136 can provide a first flow characteristic in a first orientation and a second flow characteristic in a second orientation. Specifically, the first flow characteristic can be similar to the flow characteristics of the cage 136 (see...). Figure 10 The second flow characteristic can be similar to the rapid opening characteristic of cage 2136 (see...). Figure 15 (Line 2216 in the text). However, other flow characteristics are also possible in each of the first and second orientations, including flow characteristics that can be obtained using cages with different configurations.

[0113] Additionally, some cages can be configured to provide the same flow characteristics regardless of their installation orientation. For example, Figure 17 Another example cage 6136 is shown that can be used with regulator 100 or another regulator. Cage 6136 is configured to provide the same flow characteristics in a first orientation (e.g., flow from bottom to top relative to the illustrated orientation) and an opposite second orientation (e.g., flow from top to bottom relative to the illustrated orientation). Because cage 6136 can provide the same flow characteristics in both orientations, assembly errors can be avoided, and the service life of the cage can be extended because cage 6136 can be inverted in case of damage.

[0114] Generally, cage 6136 is similar to cage 5136 and includes a peripheral wall 6140 defining a cage central opening 6142 extending between a first cage end 6144 and a second cage end 6146. Cage central opening 6142 defines a cage inner surface 6154 having a first sealing portion 6156 adjacent first cage end 6144, a gap portion 6158 toward an axial center of cage 6136, and a first transition portion 6160 extending between the first sealing portion and the gap portion. Additionally, cage inner surface 6154 also defines a second sealing portion 6218 adjacent second cage end 6146 and a second transition portion 6220 extending between second sealing portion 6218 and gap portion 6158 and connecting the second sealing portion with the gap portion.

[0115] Further, cage 6136 includes a plurality of cage apertures 6150 formed as slots in peripheral wall 5140. Similar to plurality of cage apertures 5150, each of cage apertures 6150 has a first, wider portion 6204 and a second, narrower portion 6206 disposed proximate first cage end 6144. However, cage apertures 6150 also include a third, narrower portion 6224 disposed proximate second cage end 6146. Third narrower portion 6224 is a mirror image of second narrower portion 6206. In other words, cage 6136 is symmetrical about a horizontal plane 6226 that is parallel to first cage end 6144 and second cage end 6146 and passes between the first and second cage ends. In this way, cage 6136 can provide the same flow characteristics in both a first orientation and a second orientation.

[0116] While symmetrically configured cages can have particular benefits, including those discussed with respect to cage 6136, other configurations can include variations on different sides of a reference plane or axis. For example, some cages can exhibit cage apertures having two or more narrower portions arranged somewhat similar to Figure 17 the arrangement shown, but configured to provide different flow characteristics depending on the orientation of the cage (e.g., whether installed in a first orientation or an opposite, second orientation). Similarly, some cages can include cage inner surfaces having one or more transition portions different from those shown, for example Figure 17 with respect to cage 6136.

[0117] The foregoing description of the examples disclosed enables any person skilled in the art to make or use the disclosed technology. Modifications of these examples will occur to those skilled in the art and to which the generic principles defined herein can be applied to other examples without departing from the spirit or scope of the disclosed technology. Accordingly, it is to be understood that the technology disclosed is not to be limited to the examples disclosed herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A regulator, comprising: A regulator body defining an inlet and an outlet; A seat is disposed within the regulator body along a flow path between the inlet and the outlet; A plug assembly movable relative to the seat to regulate flow along the flow path, the plug assembly including a plug and a peripheral sealing element; and A cage having a peripheral wall defining a central opening and including a plurality of cage holes extending through the peripheral wall, the cage surrounding the flow path adjacent to the seat and configured to movably receive the plug within the central opening; The peripheral sealing element is configured to contact the inner surface of the peripheral wall within the stroke range of the plug assembly to change the size of the flow region of the plurality of cages according to the position of the plug assembly along the stroke range. The flow region includes, in the flow path, the inner surface defining a sealing portion, a gap portion further away from the seat than the sealing portion, and a tapered transition portion extending between the sealing portion and the gap portion. The sealing portion is configured to provide a first radial clearance relative to the peripheral sealing element, the first radial clearance being smaller in the radial direction than a second radial clearance provided by the gap portion relative to the peripheral sealing element, and at least one of the plurality of cages extends from the gap portion through the tapered transition portion into the sealing portion to allow flow through the cage at the sealing portion.

2. The regulator according to claim 1, wherein, The plug assembly is movable between a first position along the travel range and a second position along the travel range, wherein in the first position the flow area is a first flow area, and in the second position the plug assembly is further away from the seat than in the first position and the flow area is a second flow area larger than the first flow area.

3. The regulator according to claim 2, wherein, When the plug assembly is in the first position, at least a portion of the sealing area of ​​the peripheral sealing element is not axially aligned with the plurality of cage holes; In the case where the plug assembly is in the second position, the upstream edge of the sealing area of ​​the peripheral sealing element is axially aligned with the plurality of cage holes.

4. The regulator according to claim 3, wherein, The plug assembly is also capable of moving to a third position along the range of travel, in which the plug assembly is further away from the seat than in the first and second positions; and The movement of the plug assembly from the second position to the third position causes a non-linear increase in the movement of the flow region relative to the plug assembly.

5. The regulator according to claim 4, wherein, At least one of the plurality of cage openings includes an upstream portion and a downstream portion, the downstream portion having a larger circumferential dimension than the upstream portion.

6. The regulator according to claim 1, wherein, The peripheral sealing element is configured to contact the inner surface along the sealing portion to prevent flow through the seat portion; and The peripheral sealing element is substantially detached from the inner surface along the gap portion to allow flow through the seat.

7. The regulator according to claim 1, wherein, The diameter of the inner surface at the sealing portion is smaller than the diameter of the inner surface at the gap portion.

8. The regulator according to claim 1, wherein, The plug assembly defines a circumferential groove and the peripheral sealing element is held by the circumferential groove.

9. The regulator according to claim 1, wherein, The peripheral sealing element is radially outward biased relative to the plug.

10. The regulator according to claim 9, wherein, The peripheral sealing element includes a ring, the outer diameter of which is larger than the diameter of the plug; and One or more elastic members are disposed within the groove of the plug assembly to bias the ring radially outward.

11. The regulator according to claim 1, wherein, At least one of the plurality of cage openings includes a downstream portion and an upstream portion, wherein the flow profile of the downstream portion is different from that of the upstream portion.

12. The regulator according to claim 11, wherein, The downstream portion includes a first portion having a first width, and the upstream portion includes a second portion having a second width, wherein the first width is greater than the second width, and the first portion and the second portion are continuous.

13. The regulator according to claim 11, wherein, The cage is configured to be selectively mounted in the regulator body along a first orientation or along a second orientation opposite to the first orientation; and The flow region varies depending on the position of the plug assembly along the travel range and whether the cage is installed along the first orientation or the second orientation.

14. The regulator according to claim 1, wherein, The plurality of cage openings include slots extending between the first end and the second end of the cage.

15. The regulator according to claim 14, wherein, Each of the plurality of slots extends axially into the low-flow portion of the cage, within which the peripheral sealing element is configured to sealably contact the inner surface.

16. The regulator according to claim 15, wherein, The plurality of slots exhibit multiple axial extensions of varying lengths extending into the low-flow portion of the cage.

17. An internal component assembly for a regulator, the internal component assembly comprising: A cage comprising a peripheral wall defining an opening and a plurality of cage openings formed in the peripheral wall, the opening defining a radially inner surface including a sealing portion located at a first end of the cage and having a first inner diameter, a gap portion spaced apart from the sealing portion and having a second inner diameter greater than the first inner diameter, and a tapered transition portion extending between the sealing portion and the gap portion, at least one of the plurality of cage openings extending axially from the sealing portion to the gap portion to allow flow through the peripheral wall of the cage; and A plug, comprising a sealing element, configured to be movably received within the opening to move along a range of travel, such that the sealing element contacts the radially inner surface of the cage to change the effective flow area through the plurality of cage openings based on the position of the plug along the range of travel.

18. The internal component assembly of claim 17, wherein, The plurality of cage openings includes a first opening, which has a narrower portion relative to the circumferential direction along the sealing portion and a wider portion relative to the circumferential direction along the gap portion.

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