Valve assembly and holder frame assembly

Abstract

The present invention provides a holder frame assembly for a valve and a valve assembly, the holder frame assembly comprising a first annular member and a second annular member, the first annular member and the second annular member being assembled on an O-ring seal, wherein a portion of the O-ring seal is exposed in an inner diameter gap between inner edge portions of the first and second annular members to define a seat seal.

Description

[0001] This application is a divisional application of the application filed on April 25, 2022, with application number 2022800309569 and invention title "Enhanced Valve Arrangement".

[0002] Cross - reference to related applications

[0003] This application claims the priority and all benefits of U.S. Provisional Patent Application Serial No. 63 / 180,166, titled POPPET - STYLE VALVE ARRANGEMENTS, filed on April 27, 2021, the entire disclosure of which is incorporated herein by reference. Technical Field

[0004] The present invention relates to fluid flow and delivery devices and methods, and more particularly, to poppet valves for controlling fluid flow and delivery. Background Art

[0005] It is well known that poppet valves are used as flow control mechanisms for gaseous and liquid fluid delivery, flow control, and pressure control. A poppet valve arrangement includes an axially movable stem having a sealing portion (e.g., an enlarged disk, a tapered end) that seals against an annular seat in a valve passage when the stem is in the closed position and is axially separated from the seat when the stem is in the open position, thereby permitting fluid to flow through the valve passage. Many different types of fluid control devices utilize poppet valve mechanisms, including, for example, diaphragm valves, bellows valves, and pressure regulators. Summary of the Invention

[0006] According to an exemplary embodiment of the present disclosure, a seat carrier sub - assembly for a valve includes: an annular seat carrier body including an annular protrusion that radially extends into a central passage; and an annular plastic seal ring overmolded onto the annular protrusion, wherein the annular plastic seal ring defines a seat seal.

[0007] According to another exemplary embodiment of the present disclosure, a valve assembly includes: a valve body defining a flow path between an inlet port and an outlet port; an annular seal ring surrounding an axially extending portion of the flow path between the inlet port and the outlet port; and a poppet assembled with the valve body and axially movable between a closed position and an open position. The seal ring interlocks with a protrusion that radially extends into the flow path.

[0008] According to another exemplary embodiment of the present disclosure, a seat carrier subassembly for a valve includes: a first annular member and a second annular member, the first annular member and the second annular member being assembled over an O-ring seal, wherein a portion of the O-ring seal is exposed in an inner diameter clearance between inner edge portions of the first annular member and the second annular member to define a seat seal.

[0009] According to another exemplary embodiment of the present disclosure, a lifter subassembly includes: a lifter having a central portion disposed between an axially extending upper rod portion and an axially extending lower rod portion, wherein the central portion defines an upwardly facing radially extending seal portion and a downwardly facing radially extending shoulder portion; a retaining clip fixed above an enlarged foot portion of the lower rod portion; and a lifter spring disposed around the lower rod portion and captured between the shoulder portion and the retaining clip.

[0010] According to another exemplary embodiment of the present disclosure, a pressure regulator includes: a valve body; a lifter disposed within the valve body and including an axially extending upper rod portion and a radially extending lifter seal portion; a loading mechanism assembled with the valve body and operable to apply a downward loading force; and a sensing element disposed between the loading mechanism and the lifter to transfer the loading force from the loading mechanism to the lifter. A lower end of the sensing element includes a socket receiving an enlarged head portion of the upper rod portion of the lifter, wherein the socket is sized to permit axial movement of the lifter relative to the sensing element. The pressure regulator further includes an overtravel spring disposed around the upper rod portion of the lifter and compressed between a shoulder portion of the lifter and an end face of the socket.

[0011] According to another exemplary embodiment of the present disclosure, a pressure regulator includes: a valve body module having a valve body housing block that holds a lift member and a seat seal; a loading module having a loading block that is fixedly secured adjacent to a discharge adapter block and holds a loading element configured to apply a loading force to a sensing member disposed between the loading element and the lift member; and at least one of the following: a piston module having a piston adapter block that is fixed between the valve body housing block and the loading block and holds the sensing member in engagement with the lift member, wherein the sensing member includes a piston; and a discharge module having a discharge adapter block that is fixed between the valve body housing block and the loading block and defines a discharge port in fluid communication with a discharge passage in the sensing member. The valve body housing block and at least one of the piston adapter block and the discharge adapter block each include a first assembly interface of a consistent size, and the loading block and at least one of the piston adapter block and the discharge adapter block each include a second assembly interface of a consistent size that mates and seals in engagement with the first assembly interface of an adjacent one of the valve body housing block and at least one of the piston adapter block and the discharge adapter block, such that the valve body housing block is configured to be directly assembled to the loading block by omitting each of at least one of the piston module and the discharge module.

[0012] According to another exemplary embodiment of the present disclosure, a pressure regulator includes: a valve body that holds a valve seat; a lift member disposed within the valve body and axially movable relative to the valve seat; a spring loading mechanism assembled with the valve body and operable to apply a downward loading force; and a sensing element disposed between the spring loading mechanism and the lift member to transfer the loading force from the spring loading mechanism to the lift member. The spring loading mechanism includes: a spring housing; a spring element held within the spring housing and disposed between an upper force adjustment plate and a lower spring support plate; and an adjustment handle assembled with the spring housing and including a threaded rod portion that threadedly engages the upper force adjustment plate. The upper force adjustment plate is rotatably fixed and axially slidable within the spring housing such that rotation of the adjustment handle by a user axially moves the upper force adjustment plate to adjust the downward loading force. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a cross-sectional schematic view of a lift-type valve assembly;

[0014] Figure 2A is a cross-sectional schematic view of a pressure reducing regulator valve assembly;

[0015] Figure 2B is a cross-sectional view of a back pressure regulator valve assembly;

[0016] Figure 3 is a cross-sectional view of a pressure reducing regulator valve sub-assembly according to an exemplary embodiment of the present disclosure;

[0017] Figure 3A is Figure 3 a perspective view of a lift sub-assembly of a regulator valve sub-assembly of

[0018] Figure 4 is a cross-sectional view of a back pressure regulator valve sub-assembly according to an exemplary embodiment of the present disclosure;

[0019] Figure 4A is Figure 4 a perspective view of a lift and sensing mechanism support member sub-assembly of a regulator valve sub-assembly of

[0020] Figure 5A is a cross-sectional view of a seat carrier sub-assembly according to an exemplary embodiment of the present disclosure;

[0021] Figure 5B is Figure 5A an exploded upper perspective view of a seat carrier sub-assembly of

[0022] Figure 5C is Figure 5A an exploded lower perspective view of a seat carrier sub-assembly of

[0023] Figure 6A is a cross-sectional view of a seat carrier sub-assembly according to another exemplary embodiment of the present disclosure;

[0024] Figure 6B is Figure 6A an exploded upper perspective view of a seat carrier sub-assembly of

[0025] Figure 6C is Figure 6A an exploded lower perspective view of a seat carrier sub-assembly of

[0026] Figure 7 is a cross-sectional view of a pressure reducing regulator valve with a diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure;

[0027] Figure 8 is a cross-sectional view of a back pressure regulator valve with a diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure;

[0028] Figure 9Cross-sectional view of a pressure reducing regulator valve having a high-sensitivity diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure;

[0029] Figure 10 Cross-sectional view of a back pressure regulator valve having a high-sensitivity diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure;

[0030] Figure 11 Cross-sectional view of a pressure reducing regulator valve having a piston sensing mechanism according to another exemplary embodiment of the present disclosure;

[0031] Figure 12 Cross-sectional view of a back pressure regulator valve having a piston sensing mechanism according to another exemplary embodiment of the present disclosure;

[0032] Figure 13 Cross-sectional view of a spring-loading mechanism for a pressure regulator valve assembly according to another exemplary embodiment of the present disclosure;

[0033] Figure 13A Is Figure 13 Exploded perspective view of the spring-loading mechanism;

[0034] Figure 14 Cross-sectional view of a shim-loading mechanism for a diaphragm sensing pressure regulator valve assembly according to another exemplary embodiment of the present disclosure;

[0035] Figure 15 Cross-sectional view of a shim-loading mechanism for a piston sensing pressure regulator valve assembly according to another exemplary embodiment of the present disclosure;

[0036] Figure 16 Cross-sectional view of a self-draining diaphragm sensing mechanism for a pressure regulator valve assembly according to another exemplary embodiment of the present disclosure;

[0037] Figure 17 Cross-sectional view of a self-draining piston sensing mechanism for a pressure regulator valve assembly according to another exemplary embodiment of the present disclosure;

[0038] Figure 18 Perspective view of a modular piston sensing, discharging, spring-loading pressure reducing regulator assembly according to an exemplary embodiment of the present disclosure;

[0039] Figure 19 Is Figure 18 Cross-sectional view of the modular regulator assembly;

[0040] Figure 19A Is Figure 19 Partially enlarged view of the modular regulator assembly;

[0041] Figure 20 is Figure 18 an exploded perspective view of a regulator assembly;

[0042] Figure 21 is a cross-sectional view of a modular diaphragm sensing, venting, spring-loaded pressure reducing regulator assembly in accordance with an exemplary embodiment of the present disclosure;

[0043] Figure 22 is a cross-sectional view of a modular piston sensing, non-venting, spring-loaded pressure reducing regulator assembly in accordance with an exemplary embodiment of the present disclosure;

[0044] Figure 23 is a cross-sectional view of a modular diaphragm sensing, non-venting, spring-loaded pressure reducing regulator assembly in accordance with an exemplary embodiment of the present disclosure; and

[0045] Figure 24 is a cross-sectional view of a modular diaphragm sensing, non-venting, spring-loaded back pressure regulator assembly in accordance with an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0046] This detailed description only describes exemplary embodiments and is not intended to limit the scope of the claims in any way. In fact, the claimed invention is broader than the exemplary embodiments and is not limited thereby, and the terms used in the claims have their full ordinary meaning. For example, while the specific embodiments described herein relate to pressure reducing and back pressure regulator valve arrangements, the features of the present application may additionally or alternatively be applied to other types of valves, including, for example, user-operable regulating valves, stop valves, check valves, and pressure relief valves. As used herein, the terms "lift valve" and "lift-type valve" are intended to broadly include any valve having a stem that carries a flow restricting member that moves relative to an annular seat by longitudinal movement of the stem and that may but need not be movable into sealing engagement with the valve seat. Except for gas-tight or liquid-tight seals, the terms "seal" and "sealing engagement" are intended to include situations where there is a reduction in flow due to contact between a sealing surface and a seating surface.

[0047] While the various inventive aspects, concepts, and features of the present invention may be described and shown herein as embodied in combination in exemplary embodiments, these various aspects, concepts, and features may be used singly or in various combinations and sub - combinations in many alternative embodiments. All such combinations and sub - combinations are intended to fall within the scope of the present invention unless expressly excluded herein. Further, although various alternative embodiments of the present invention with respect to the various aspects, concepts, and features (such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives with respect to form, assembly, and function, etc.) may be described herein, such description is not intended to be a complete or exhaustive listing of available alternative embodiments (whether currently known or later developed). One of ordinary skill in the art may readily incorporate one or more of the inventive aspects, concepts, or features into additional embodiments and uses within the scope of the present invention even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts, or aspects of the present invention may be described herein as preferred arrangements or methods, such description is not intended to imply that such features are required or necessary unless expressly stated to be the case. Further, exemplary or representative values and ranges may be included to assist in understanding the disclosure; however, such values and ranges should not be construed in a limiting sense but are intended to be critical values or ranges only when expressly stated to be the case. A parameter identified as “approximate” or “about” a specified value is intended to include both the specified value and values within 10% of the specified value unless otherwise expressly stated. Additionally, it should be understood that the accompanying drawings of this application may or may not be drawn to scale and may thus be understood to teach various ratios and proportions apparent in the drawings. Moreover, although various aspects, features, and concepts may be expressly identified herein as being inventive or forming part of the present invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts, and features that are fully described herein but not expressly so identified or identified as part of a specific invention, and the present invention is alternatively set forth in the appended claims. The description of an exemplary method or process is not limited to including all steps required in all cases, and the order of presentation of steps should not be construed as required or necessary unless expressly stated to be the case.

[0048] Reference Figure 1, in the exemplary embodiment schematically shown, the lift valve assembly 10 includes a valve body 20 defining a valve passageway 22 between an inlet port 21 and an outlet port 23 and an annular valve seat 30 extending axially around a central portion 24 of the valve passageway. A lift member 40 is assembled with the valve body 20 and includes an axially extending lift member stem 41 and a radially extending lift member seal portion 42. An actuator or loading mechanism 50 is assembled with the lift member stem 41 to control the axial movement of the lift member 40 between a closed position in which the lift member seal portion 42 seals against the valve seat 30 (e.g., to prevent flow exceeding an allowable leakage rate) and an open position in which the lift member seal portion is axially separated from the valve seat to permit fluid flow through an axially extending portion 24 of the valve passageway 22. The actuator 50 can be user-operated (e.g., manually, pneumatically, or electrically) for selectively moving the lift member 40. Alternatively, the actuator 50 can be configured to automatically move or permit the movement of the lift member under certain predetermined system conditions. For example, the actuator arrangement can be configured to cause or permit the lift member 40 to move automatically at a threshold system fluid pressure, e.g., to relieve excessive fluid pressure from the system (in the case of a pressure relief valve), prevent backflow (in the case of a check valve), or reduce the outlet pressure (in the case of a pressure regulator). An example of a pressure regulator having a lift valve arrangement is disclosed in a product catalog titled PRESSURE REGULATORS RHPS SERIES, which is publicly available online and otherwise from Swagelok Company and is hereby incorporated by reference in its entirety.

[0049] Figure 2A Schematically shown is a pressure reducing regulator 10a having a regulating mechanism that includes a sensing element 80a (e.g., a piston or diaphragm) whose upper side is subjected to a load force F applied by a loading mechanism 50a (e.g., a compression spring or a fluid pressurized chamber) S for a downwardly biased movement of the lift member 40a. The lower side of the sensing element 80a is subjected to the force F of the system fluid such that when the system fluid force F exceeds the biasing element load force F S , an upward movement of the lift member 40a is provided (e.g., by direct attachment of the lift member or a separately driven movement). The load force F S biases the lift member 40a toward the open position out of sealing engagement with the valve seat 32a. When the downstream fluid pressure exceeds the desired pressure, corresponding to the system fluid force F exceeding the biasing element load force F S , the sensing element 80a moves upward to provide an upward movement of the lift member relative to the valve seat 32a toward the closed position, thereby reducing the outlet pressure. When the downstream fluid pressure decreases to or below the desired pressure, the biasing element load force F SOvercome the system fluid force F to effect downward movement of the sensing element 80a to provide downward movement of the lifter 40a toward the open position.

[0050] Figure 2B A back pressure regulator 10b is schematically shown, similar to Figure 2A the pressure reducing regulator 10a, which has an adjustment mechanism that includes a sensing element 80b (e.g., a piston or diaphragm) whose upper side is subjected to a load force F applied by a loading mechanism 50b (e.g., a compression spring or a fluid pressurized chamber) S to effect a downward biasing movement of the lifter 40b. The lower side of the sensing element 80b is subjected to the force F of the system fluid, such that when the system fluid force F exceeds the loading mechanism load force F S a upward movement of the lifter 40b is provided. The load force F S biases the lifter 40b toward the closed position so as to sealingly engage with the valve seat 32b. When the upstream fluid pressure exceeds the desired pressure, corresponding to the system fluid force F exceeding the loading mechanism load force F S the sensing element 80b moves upward to provide an upward movement of the lifter relative to the valve seat 32b toward the open position, thereby reducing the inlet or upstream pressure. When the upstream fluid pressure decreases to or below the desired pressure, the loading mechanism load force F S overcomes the system fluid force F to effect downward movement of the sensing element 80b to provide downward movement of the lifter 40b toward the closed position.

[0051] Many different regulator valve bodies, lifters, and seat arrangements can be utilized in a variety of combinations. Figure 3 An exemplary pressure reducing regulator valve subassembly 101 is shown, which includes a regulator valve body 110 defining a valve passage 112 between an inlet port 111 and an outlet port 113 and an annular valve seat sealing surface 132 disposed in an axially extending central cavity 114 of the valve body between the inlet port and the outlet port. The lifter 140 is assembled with the valve body 110 and includes an axially extending upper lifter rod 141 for engaging (directly or indirectly) the sensing element and a radially extending lifter sealing portion 142, wherein the lifter is axially movable between a lower open position and an upper closed position, in the lower open position, the lifter sealing portion is axially spaced from the seat sealing surface 132, and in the upper closed position, the lifter sealing portion sealingly engages with the valve seat sealing surface. The outlet port 113 is in fluid communication with a sensing interface chamber 119 at least partially defined by the upper end of the valve body 110. In this arrangement, a downward force applied to the lifter 140 by a sensing mechanism (described in more detail hereinafter) that exceeds the upward force applied by the outlet fluid pressure causes the lifter to move toward the lower open position.

[0052] In the illustrated example, the valve body 110 includes a body housing 115 and a body plug 120 assembled (e.g., threadedly engaged) with a central cavity 114 of the housing, and a valve seat sealing surface 132 is disposed on a seat carrier 130 retained within the central cavity of the housing.

[0053] As Figure 3 shown, the body housing 115 may be provided with a support ring 105 sized to support the regulator in an upright position (e.g., on a workbench) prior to installation. The support ring 105 may be provided in flexible plastic (e.g., nylon) to facilitate snap (and unsnap) engagement with a lower lip 115-1 on the body housing 115. After installation, the support ring 105 may be removed or retained with the regulator, e.g., as a visual indicator (e.g., color code, text, or symbol). In other embodiments, the support ring may provide attachment of additional hardware or devices. For example, as Figure 7 shown, a heater block 102 (or other stationary block) may be secured to the support ring 105 using a threaded fastener 106 that passes through a mounting aperture 107 in the support ring and is threaded into a mounting hole 103 in the heater block 102.

[0054] The exemplary body plug 120 includes a central cavity 121 that receives a lower stem portion 143 of a lifter 140, an upper end face 122 that engages the seat carrier 130 to secure the seat carrier to a first counterbore 116 of the central cavity 114, and one or more apertures 123 that are arranged to align with a valve body inlet port 111 to allow fluid to flow from the inlet port into the body plug cavity 121 when the lifter 140 is in an open position and flow between the lifter seal portion 142 and the valve seat sealing surface 132 to an outlet port 113. The apertures 123 may be circumferentially spaced about the body plug 120 to ensure alignment of the inlet port 111 with at least one of the apertures regardless of the rotational position of the body plug within the valve body housing 115. The seat carrier 130 may be provided with an outer annular groove 133 for a retaining washer or O-ring seal 134 for sealing engagement with the first counterbore 116. The body plug end face 122 may be configured to engage a second counterbore 117 in the central cavity 114, e.g., to limit axial compression of the seat carrier 130.

[0055] As shown, the lift member 140 may be provided with an internal passage 145 extending from the lower stem portion 143 of the lift member to the upper portion of the lift member downstream of the seat sealing surface 132, where a gasket seal 147 provides a seal between the enlarged lower foot portion 148 of the lower stem portion of the lift member and the narrower base portion 125 of the body plug cavity 121 such that when the lift member 140 is in the closed position, the inlet or upstream fluid pressure on the lift member is counteracted by the outlet or downstream fluid pressure. This arrangement may be referred to as a balanced lift member design, which may provide, for example, reduced seat loading, such as to reduce wear / deformation of the seat sealing surface 132. In such an arrangement, a lift member spring 146 may be disposed in the body plug cavity 121, compressed between the body plug 120 and the lift member 140 (e.g., at shoulder 144) to provide a consistent closing / sealing force acting on the lift member independent of the system fluid pressure.

[0056] To facilitate the assembly of the pressure reducing regulator valve subassembly 101, the lift member spring 146 may be pre-assembled with the lift member 140 as a lift member subassembly, e.g., in an uncompressed or partially compressed condition, thus allowing initial engagement of the body plug threads with the housing threads without having to compress the spring. Once the body plug 120 is partially threadedly connected to the central cavity 114, full threaded installation of the body plug in the central cavity completes the desired compression of the lift member spring 146, where the body plug end face 122 abuts the second counterbore 117 to provide a hard stop for the threaded installation. Although many different arrangements may be used to provide a pre-assembled spring for the lift member, in the illustrated embodiment, as Figure 3A more clearly shown, an E-clip or other such retaining clip 109 is fixed above the enlarged foot portion 148 of the lower lift member stem 143, thus providing a lower support surface for the lift member spring 146. The spring 146 may or may not be pre-compressed or spring loaded between the lift member shoulder 144 and the retaining clip 109. The body plug cavity 121 may include a shallow annular recess or counterbore 124 sized to receive and align the retaining clip 109.

[0057] In an exemplary method, to assemble the seat carrier 130, lift member 140, and body plug 120 with the valve body housing 115, the seat carrier 130 is inserted into the housing through the lower end of the central cavity 114. The lift member 140 with the pre-assembled lift member spring 146 is installed in the central cavity 114, where the upper lift member stem 141 extends through the central hole in the seat carrier 130. The body plug is installed above the lower lift member stem 143 and threadedly connected to the valve body housing 115 to secure the seat carrier 130 against the first counterbore 116, where the body plug counterbore 124 engages the retaining clip 109 to move the retaining clip away from the foot portion 148 of the lower lift member stem 143 and compress the lift member spring 146 to the desired degree of compression.

[0058] Figure 4 An exemplary backpressure regulator valve subassembly 201 is shown, which includes a regulator valve body 210 defining a valve passage 212 between an inlet port 213 and an outlet port 211, and an annular valve seat sealing surface 232 disposed in an axially extending central cavity 214 of the valve body between the inlet port and the outlet port. A lifter 240 is assembled with the valve body 210 and includes an axially extending upper lifter rod 241 for engaging (directly or indirectly) a sensing mechanism and a radially extending lifter seal portion 242, wherein the lifter is axially movable between a lower closed position in which the lifter seal portion is in sealing engagement with the seat sealing surface 232 and an upper open position in which the lifter seal portion is axially spaced from the seat seal. The inlet port 213 is in fluid communication with a sensing interface chamber 219 defined at least in part by an upper end of the valve body housing 215. In this arrangement, a downward force applied to the lifter 240 by a sensing mechanism (described in more detail hereinafter) that exceeds an upward force applied by the inlet fluid pressure causes the lifter to move toward the lower closed position.

[0059] While the valve body may be provided as a single-piece or integral component including an integrally formed valve seat, in other embodiments, the valve body may include a multi-component assembly, such as to facilitate the installation and / or replacement of the lifter, valve seat, or other such components. In the example shown, the valve body 210 includes a valve housing 215 and a body plug 220 assembled (e.g., threadedly engaged) with the central cavity 214 of the housing, and the valve seat sealing surface 232 is disposed on a seat carrier 230 retained in the central cavity of the housing.

[0060] The exemplary body plug 220 includes a central cavity 221 for receiving a lower rod portion 243 of the lifter 240, an upper end face 222 for engaging the seat carrier 230 to secure the seat carrier in a first counterbore 216 of the central cavity 214, and one or more apertures 223 arranged to align with the valve body outlet port 211 to allow fluid to flow from the inlet port 213, through between the lifter seal portion 242 and the valve seat sealing surface 232, into the body plug cavity 221, and through the apertures 223 to the outlet port 211 when the lifter 240 is in the open position. The apertures 223 may be circumferentially spaced around the body plug 220 to ensure alignment of the outlet port 211 with at least one of the apertures, regardless of the rotational position of the body plug within the valve body housing 215. The seat carrier 230 may be provided with an annular end face groove 235 for receiving a retaining washer / O-ring seal 236 for sealing engagement with the first counterbore 216. The body plug end face 222 may be configured to engage a second counterbore 217 in the central cavity 214, such as to limit axial compression of the seat carrier 230.

[0061] As shown, the lift member 240 may be provided with an internal passage 245 extending from the lower stem portion 243 of the lift member to the upper portion of the lift member upstream of the seat sealing surface 232, where a gasket seal 247 provides a seal between the enlarged lower foot portion 248 of the lower stem portion of the lift member and the narrower base portion 225 of the main body plug cavity 221 such that when the lift member 240 is in the closed position, the inlet or upstream fluid pressure on the lift member is counteracted by the outlet or downstream fluid pressure. This arrangement may be referred to as a balanced lift member design, which may provide, for example, a reduced seat load, such as to reduce seat wear / deformation.

[0062] In a backpressure regulator valve subassembly, the seat may also be protected from excessive lift member closing force applied by the sensing mechanism by an overtravel spring disposed between the sensing mechanism and the lift member sealing portion, thereby allowing further downward axial travel of the sensing mechanism when the lift member sealing portion engages the seat seal. According to an exemplary aspect of the present disclosure, the lift member may be interlocked with a support member of the sensing mechanism using a joint configured to allow limited axial movement of the lift member relative to the sensing mechanism support member, where the overtravel spring is captured between opposing surfaces of the lift member and the sensing mechanism support member. This joint arrangement may facilitate assembly of the lift member and the sensing mechanism together.

[0063] Although many different joint arrangements may be utilized, in an exemplary embodiment, one of the lift member and the support member is provided with an enlarged or flanged head portion, while the other of the lift member and the support member includes a slotted socket portion that retains the head portion, where the overtravel spring is compressed between portions of the lift member and the support member such that the overtravel spring biases the sealing portion of the lift member away from the support member. When the load force of the sensing mechanism moves the lift member to the closed position, the excessive closing force from the sensing mechanism causes the overtravel spring to be compressed between the lift member and the support member, thereby limiting the closing force applied by the lift member to the seat seal.

[0064] In the example shown, also as Figure 4A shown, the enlarged or flanged head portion 249 of the lift member 240 is received in the slotted socket portion 289 of the sensing mechanism support member 282, and the overtravel spring 246 is compressed between the lower end face 287 of the support member and the upper shoulder 244 of the lift member 240 such that the overtravel spring 246 biases the sealing portion 242 of the lift member away from the support member. When the load force of the sensing mechanism moves the lift member 240 to the closed position, the excessive closing force from the sensing mechanism causes the overtravel spring 246 to be compressed between the lift member and the support member 282, thereby limiting the closing force applied by the lift member to the seat sealing surface 232.

[0065] In an exemplary method, to assemble the seat carrier 230, the lifter 240, and the body plug 220 with the valve body housing 215 of the back pressure regulator valve arrangement 201, the overtravel spring 246 is slid over the upper lifter rod 241, and the head portion 249 of the lifter is inserted into the slotted socket portion 289 of the sensing mechanism support member 282 such that the overtravel spring 246 is compressed between the lifter and the support member. The lifter 240 is inserted into the housing 215 through the upper end of the central cavity 214, and the seat carrier 230 is inserted into the housing through the lower end of the central cavity 214. The body plug 220 is mounted on the lower lifter rod 243 and threadedly engaged with the valve body housing 215 to secure the seat carrier 230 against the first counterbore 216.

[0066] For example, many different types of seat carrier assemblies can be utilized to accommodate different system pressures, temperatures, and fluid / chemical characteristics. In Figure 3 and Figure 4 exemplary embodiments, the seat carriers 130, 230 include an annular one-piece seat 131, 231 having a profile inner diameter that defines a seat sealing surface 132, 232. The seat carriers 130, 230 can be provided from any suitable material, including for example plastics such as polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), and polyetheretherketone (PEEK). In the pressure reducing regulator valve subassembly 101, the seat carrier includes a retaining washer seal 134 for sealing engagement with the first counterbore 116 in an outer annular groove 133. In the back pressure regulator valve subassembly 201, the seat carrier 230 includes a retaining washer seal 236 for sealing engagement with the first counterbore 216 in an annular end face groove 235.

[0067] In some applications, for example, in high pressure and / or high temperature applications, using harder materials (e.g., materials having at least 90 Shore D hardness) (e.g., metals (e.g., stainless steel)) for the seat and seal portions may be more prone to seat leakage, for example, due to seat seal misalignment, surface inconsistencies, contamination, or wear. Minor leakage, especially minor leakage at high pressures, can cause corrosion of the sealing surface, leading to more severe leakage past the valve seat. Additionally, in some valve assemblies, the closing force applied to the lifter rod may be minimal such that the forced deflection or deformation of the seat and seal portions is insufficient to compensate for the sealing surface misalignment.

[0068] According to one aspect of the present disclosure, the valve seat can be provided as an overmolded, overlying or otherwise interlocked annular softer material (e.g., having a hardness of less than about 100 HRM) sealing ring that is fixed to or retained on a harder (e.g., hardness greater than about 80 HRB) inner circumferential rib, flange, rail or other such protrusion that protrudes into the central portion of the valve passage. The rigid lower protrusion allows the use of a relatively thin (e.g., between about 0.05 inches and about 0.10 inches) sealing ring, thereby minimizing thermal expansion, material flow and deformation of the softer sealing ring material, while providing a rigid support to facilitate use in higher pressure (e.g., up to about 6000 psi) applications.

[0069] Figure 5A , Figure 5B and Figure 5C An exemplary ring-shaped seat bracket subassembly 330 is shown, similar to Figure 3 and Figure 4 The seat bracket 130, 230 of the present invention comprises a seat bracket 331 having an inner peripheral annular protrusion 338 and an annular sealing ring 337 overmolded on, overlying, or otherwise interlocked with the annular protrusion. The sealing ring 337 defines a seat sealing surface 332 that is contoured for sealing engagement with a poppet sealing portion (e.g., as Figure 3 and Figure 4 338 is formed as an annular, circumferentially continuous, and generally T-shaped rail that includes a narrower neck portion and an enlarged head portion that is shaped to maintain interlocking engagement with a complementary shaped channel portion 339 of the sealing ring 337. In other embodiments, the protrusion may have a different cross-sectional shape, and / or may be circumferentially discontinuous, e.g., the cross-sectional shape varies around the circumference, or is formed of two or more circumferentially spaced segments.

[0070] Similar to Figure 3 and Figure 4 The seal ring 130, 230 of the seat bracket 330 may include: a first annular groove 333 (e.g., an outer annular groove) that retains a gasket seal 334 for use with a countersunk hole in the valve body (e.g., Figure 4 The counterbore 116 in the pressure reducing regulator valve subassembly 101 of the pressure reducing regulator is sealingly engaged to provide a downward facing seat sealing surface 332; and / or a second annular groove 335 (e.g., an annular end face groove 335) that retains a gasket seal 336 for use with a counterbore in the valve body (e.g., with a Figure 4 The countersunk hole 216 in the back pressure regulator valve subassembly 201 is sealingly engaged to provide an upward facing seat seal.

[0071] Although the seal ring can be press - fit or otherwise assembled over the protrusion, in other embodiments, the seal ring 337 can be injection - molded or over - molded onto the annular protrusion 336, which can provide consistent roundness, surface finish, and material thickness of the seal ring. A variety of injection - molding methods can be employed. In an exemplary arrangement, injection - molding using a diaphragm gate into a non - critical location g spaced from the face - seal surface 332 of the seal - ring inner diameter can prevent injection - molding flow lines of the seal ring and any resulting non - uniform shrinkage and inconsistent roundness.

[0072] In other embodiments, additive manufacturing (e.g., 3D printing) can be utilized to form the seal ring over the underlying protrusion. Examples of additive - manufacturing techniques that can be utilized include, for example: laser powder bed fusion (direct metal laser sintering or "DMLS", selective laser sintering / fusion or "SLS / SLM", or laminated additive manufacturing or "LAM"), electron beam powder bed fusion (electron beam melting or "EBM"), ultrasonic additive manufacturing ("UAM"), or direct energy deposition (laser powder deposition or "LPD", laser wire deposition or "LWD", laser engineered net shaping or "LENS", electron beam wire deposition).

[0073] Any suitable material can be used to provide sufficient sealing performance within the valve. For example, the seal ring can be provided by a suitable plastic (e.g., PEEK), and the seal - ring retaining protrusion can be provided by a metal (e.g., stainless steel). The gasket / O - ring seal can be formed from a suitable elastomer (e.g., ethylene propylene diene monomer (EPDM), perfluoroelastomer, or nitrile).

[0074] In other embodiments (not shown), the seal - ring retaining protrusion can be integrally formed with the valve body (e.g., as a protrusion into the valve - body passage), thereby eliminating a separate seat - carrier component.

[0075] According to another aspect of the present disclosure, the valve - seat seal can be defined by an elastomeric gasket or O - ring, for example to provide effective sealing in lower - pressure (e.g., less than about 1000 psi) applications. Although the O - ring / gasket seat seal can be carried by the lifter, in other embodiments, the seat - carrier arrangement can be configured to securely hold the O - ring gasket seal to provide a seat seal for the lifter (e.g., a one - piece lifter). In an exemplary embodiment, the seat carrier can include a separate first annular component and a separate second annular component that are assembled (e.g., loosely assembled) over the O - ring seal, wherein a portion of the O - ring seal is exposed in an inner - diameter gap between the inner - edge portions of the first annular component and the second annular component. The limited exposure of the O - ring seal can minimize extrusion, pinching, or other damage to the O - ring during valve actuation.

[0076] Figure 6A , Figure 6B and Figure 6C illustrate an exemplary annular seat carrier assembly 430, similar to Figure 4 , FIG. 5, and Figures 6A to 6B seat carriers 130, 230, 330, the annular seat carrier assembly including a first annular member 431-1 and a second annular member 431-2, the first annular member and the second annular member being assembled above an O-ring seal 437, wherein a portion of the O-ring seal is exposed in an inner diameter gap between inner edge portions of the first annular member and the second annular member to define a seat seal portion 432. The first annular member 431-1 and the second annular member 431-2 can be sized and configured such that when the seat carrier 430 is installed in a regulator valve subassembly (e.g., where the seat carrier is fixed between a body plug and a counterbore in a valve housing), the first annular member and the second annular member compress the O-ring seal 437 to squeeze the seat seal portion 432 of the O-ring seal through the inner diameter gap 468 between the first annular member and the second annular member.

[0077] In the illustrated embodiment, the first outer annular member 431-1 includes a radially inwardly extending flange 461 that defines an inner counterbore 462 and an axially upwardly (along the Figure 6A orientation) extending flange 463 that defines an outer counterbore 464. The second inner annular member 431-2 includes an outer peripheral portion 465 that sits in the outer counterbore 464 of the outer annular member 431-1 and an axially downwardly extending flange 466 that extends toward the radially inwardly extending flange 461 of the outer annular member to define an annular cavity 467 and an inner diameter gap 468 for the O-ring seal.

[0078] Similar to Figure 3 , Figure 4 and Figures 5A to 5C sealing rings 130, 230, 330, the seat carrier 430 can include: a first annular groove 433 (e.g., an outer annular groove) that holds a washer seal 434 for sealing engagement with a counterbore in a valve body (e.g., with the Figure 3 counterbore 116 in the pressure reducing regulator valve subassembly 101 of Figure 4 ) to provide a downward facing seat seal 432; and / or a second annular groove 335 (e.g., an annular end face groove) that holds a washer seal 436 for sealing engagement with a counterbore in a valve body (e.g., with the

[0079] Any suitable material can be used to provide sufficient sealing performance within the valve. For example, the seat carrier annular member can be provided by a metal (e.g., stainless steel) material, and the gasket / O-ring seal can be provided by a suitable elastomer (e.g., EPDM, perfluoroelastomer, or nitrile).

[0080] In other embodiments (not shown), one of the first annular member and the second annular member can be integrally formed with the valve body, thereby eliminating one of the separate seat carrier components.

[0081] According to another aspect of the present disclosure, one or more regulator valve subassembly components can be configured to facilitate modular interchangeability of components in multiple regulator assemblies, including, for example: different flow regulation arrangements (e.g., pressure reducing regulation, back pressure regulation), different types of seat seals (e.g., hard plastic, soft elastomer), different loading mechanisms (e.g., spring loading mechanism and / or Belleville spring loading mechanism), different regulator sensing mechanisms (e.g., diaphragm sensing mechanism, piston sensing mechanism), and other optional features (e.g., self-draining arrangement).

[0082] For example, as Figure 3 and Figure 4 shown, the valve body (e.g., valve body housing 115 / 215 and valve body plug 120 / 220) can be configured for use with a pressure reducing regulator and a back pressure regulator. As shown, the first port 111 / 211 of the valve body housing 115 / 215 serves as the inlet port for the pressure reducing regulator valve ( Figure 3 ) and the back pressure regulator valve ( Figure 4) outlet port, while the second port 113 / 213 of the valve body housing serves as the outlet port of the pressure reducing regulator valve and the inlet port of the back pressure regulator valve. To accommodate the enlarged head-socket joint of the back pressure regulator valve arrangement (described in more detail above), the central cavity 114 / 214 of the valve body housing 115 / 215 may be provided with an enlarged upper recess 118 / 218 sized to receive the slotted socket portion 289 of the support member 282 and the lower end face 287. To guide the upper lift rod 141 of the pressure reducing regulator valve arrangement, a guide ring 170 may be installed in the enlarged upper recess 118 / 218 to closely receive the upper lift rod. Although many different guide rings may be utilized, in the illustrated embodiment, the guide ring 170 includes a first annular guide ring element 171 and a second annular guide ring element 172 that capture an O-ring 173 that provides a guiding seal for the upper lift rod 141. The enlarged upper recess 118 / 218 and the first guide ring element 171 may include mating threads for threadably retaining the guide ring 170 in the valve body housing 115. As shown, the valve body housing 115 / 215 may include a bypass passage 113-1 / 213-1 extending from the second port 113 / 213 to the sensing interface chamber 119 / 219 for pressurizing the sensing mechanism in the pressure reducing regulator valve arrangement.

[0083] The same valve body housing 115 / 215 and valve body plug 120 / 220 are used for both the pressure reducing regulator arrangement and the back pressure regulator arrangement to provide a uniform recess between the first counterbore 116 / 216 and the second counterbore 117 / 217 to hold the seat brackets for both arrangements. As Figure 3 , Figure 4 , Figures 5A to 5C and Figures 6A to 6C shown, the seat brackets 130 / 230, 330, 430 may be provided with a first annular groove (e.g., outer annular grooves 133 / 233, 333, 433) and a second annular groove (e.g., end face annular grooves 135 / 235, 335, 435) for both the pressure reducing regulator valve arrangement and the back pressure regulator valve arrangement. When the seat brackets 130 / 230, 330, 430 are installed with the seat seal surfaces 132, 332, 432 oriented downward to engage the lift seal portion 142 of the pressure reducing regulator lifter 140 ( Figure 3) When in the state, the washer / O-ring seals 134, 334, 434 are held in the first annular grooves 133 / 233, 333, 433 for sealing engagement with the first counterbore 116. When the seat brackets 130 / 230, 330, 430 are installed with the seat sealing surfaces 132, 332, 432 facing upward to engage with the lift seal portion 242 of the back pressure regulator lift member 240, the washer / O-ring seals 136, 336, 436 are held in the second annular grooves 135 / 235, 335, 435 for sealing engagement with the first counterbore 216 ( Figure 4 ) In the back pressure regulator valve subassembly 201, the seat bracket 230 includes an annular end face groove 235 that holds the washer seal 236 for sealing engagement with the first counterbore 216.

[0084] For example, in lower outlet pressure applications (e.g., spring-loaded assemblies used with up to about 600 psi outlet pressure) and in applications where it is desired to sense changes in the outlet pressure with higher accuracy, the diaphragm sensing mechanism can be adapted to be used with the modular pressure reducing regulating valve arrangement and the modular back pressure regulating valve arrangement as described herein.

[0085] In Figure 7 the illustrated embodiment, the diaphragm sensing mechanism 580 shown together with the pressure reducing regulator valve subassembly 101 of Figure 3 includes a flat, flexible material disk (e.g., elastomer, plastic, or metal suitable for the system fluid), thus forming a diaphragm 581 that has an outer periphery clamped or fixed between the body surfaces (e.g., between the valve body housing block 115 and the opposite surfaces of the spring or leaf spring loaded housing block, tightened by a threaded screw arrangement). As shown, the diaphragm sensing mechanism 580 may include a diaphragm screw or support member 582 installed through a central opening in the diaphragm 581 to provide a more rigid engagement between the diaphragm and the lift member 140 and the loading mechanism (described below), e.g., to protect the diaphragm from damage. In the illustrated example, the upper plate 583 and the lower plate 584 are fixed to the diaphragm screw 582 on either side of the diaphragm 581 by nuts 585 threaded onto the diaphragm screw to provide additional support for the diaphragm.

[0086] In Figure 8 the illustrated embodiment, the diaphragm sensing mechanism 680 shown together with the back pressure regulator valve subassembly 201 of Figure 4 can use the same diaphragm 581 / 681, upper plate 583 / 683, lower plate 584 / 684, and nuts 585 / 685 as the diaphragm sensing mechanism 580 of Figure 7 , except that the diaphragm screw or support member 682 has a lower portion that defines a lift member head retaining socket 689 and an overtravel spring engaging end face 687, similar to Figure 4As shown and described above.

[0087] For example, a diaphragm sensing mechanism with a larger diaphragm used in applications where it is desired to sense changes in outlet pressure with even greater accuracy / sensitivity can be adapted to be used with the modular pressure reducing regulator arrangement and the modular back pressure regulator arrangement as described herein.

[0088] In Figure 9 the embodiment shown, the high-sensitivity diaphragm sensing mechanism 780 shown with the pressure reducing regulator valve subassembly 101 of Figure 3 includes an enlarged diaphragm 781 having an outer periphery that is clamped or fixed between an upper diaphragm housing member 781-1 and a lower diaphragm housing member 781-2 that can be fixed to each other by a threaded screw arrangement and bolted to the valve body housing block 115 (e.g., through mounting holes in the lower diaphragm housing member). As shown, the diaphragm sensing mechanism 780 can include a diaphragm screw or support member 782 mounted through a central opening in the diaphragm 781 to provide a more rigid engagement between the diaphragm and the lifter 140 and the loading mechanism (described below), e.g., to protect the diaphragm from damage. In the example shown, an upper plate 783 and a lower plate 784 are fixed to the diaphragm screw 782 on either side of the diaphragm 781 by nuts 785 threaded onto the diaphragm screw to provide additional support for the diaphragm.

[0089] In Figure 10 the embodiment shown, the high-sensitivity diaphragm sensing mechanism 880 shown with the pressure reducing regulator valve subassembly 201 of Figure 4 can use the same diaphragm 781 / 881, upper plate 783 / 883, lower plate 784 / 884, and nuts 785 / 885 as the diaphragm sensing mechanism 780 of Figure 9 except that the diaphragm screw or support member 882 has a lower portion that defines a lifter head retaining socket 889 and an overtravel spring engagement end face 887, similar to Figure 4 as shown and described above.

[0090] For example, a piston sensing mechanism used in higher pressure spring-loaded applications (e.g., about 600 psi) and in applications where greater resistance to damage caused by pressure spikes is desired can be adapted to be used with the modular pressure reducing regulator arrangement and the modular back pressure regulator arrangement as described herein.

[0091] In Figure 11 the embodiment shown, with Figure 3The piston sensing mechanism 980 shown together with the pressure reducing regulator valve subassembly 101 includes an axially elongated piston member 982 received in a central piston bore 984 of a piston adapter plate or block 983 that is secured between opposing surfaces of the body (e.g., between the valve body housing block 115 and the opposing surface of a spring or leaf spring loaded housing block, tightened by a threaded screw arrangement). Although many different types of sensing piston members may be used, in the illustrated embodiment, the piston member 982 includes a stepped configuration that allows adjustment of the fluid driven load applied to the piston by selecting the stepped diameters around which O-ring seals 988-1, 988-2, 988-3 are disposed to vary the upper surface of the piston upon which fluid pressure acts. The central piston bore 984 of the piston adapter block 983 is sized and shaped to accommodate the stepped piston configuration. Additionally, the lower end of the piston adapter block 983 may be shaped to conform to the upper end of the valve housing 115 / 215 such that the same valve housing may be used with both the diaphragm sensing mechanism 580 and the piston sensing mechanism 980. Additionally, a gasket seal 981 may be provided between the valve body housing block 115 and the piston adapter block 983.

[0092] In Figure 12 the illustrated embodiment, the piston sensing mechanism 1080 shown together with Figure 4 the back pressure regulator valve subassembly 201 may use the same piston adapter block 983 / 1083 as Figure 12 the piston sensing mechanism 980, except that the piston member 1082 has a lower portion that defines a lift piece head retaining socket 1089 and an overtravel spring engagement end face 1087, similar to Figure 4 that shown and described above.

[0093] A spring loading mechanism for manual adjustability of, for example, the regulator pressure setting may be adapted to be used with the modular pressure reducing regulating valve arrangement and the back pressure regulating valve arrangement (having both a diaphragm sensing mechanism and a piston sensing mechanism), as described herein.

[0094] In Figure 13In the illustrated embodiment, the spring-loading mechanism 1150 includes an elastically compressible spring element (e.g., one or more helical springs) 1152 that is retained within a spring housing 1151 that is assembled with the valve body (e.g., by mounting screws passing through a perforated mounting base 1151-1 of the spring housing), and is compressed between an upper force adjustment plate 1153 and a lower spring support plate 1154 to apply a load force to a sensing mechanism support member 1182 (e.g., a piston or diaphragm screw). As shown, the diaphragm screws 582, 682 and piston members 982, 1082 of the modular assembly may include consistent load-engaging upper end portions 586, 686, 786, 886, 986, 1086, 1186 to accommodate use of the spring-loading mechanism 1150 with either the modular pressure-reducing regulating valve arrangement or the back-pressure regulating valve arrangement described herein (having both a diaphragm sensing mechanism and a piston sensing mechanism).

[0095] The force adjustment plate 1153 can be adjusted (e.g., raised or lowered) to adjust the magnitude of the spring force applied to the sensing mechanism support member 1182 through the spring support plate 1154. Although many different spring adjustment mechanisms can be utilized, in the illustrated example, a knob handle 1155 is assembled with the spring housing 1151 and secured with a threaded rod 1156 such that the handle and threaded rod can be rotated to drive the rotatably secured force adjustment plate 1153 up and down to adjust the compression of the spring 1152. The force adjustment plate 1153 is rotatably secured by a retaining screw 1157 (or other suitable protrusion) on the plate that is located within a vertical slot 1158 in the spring housing 1151, where the slot is sized to provide a desired upper and lower limit for the force adjustment plate. A cover panel 1159 can be installed in the slot 1158, e.g., to block debris, moisture, or other contaminants.

[0096] A diaphragm-sensing leaf spring loading arrangement for remote adjustability, e.g., of regulator pressure settings, can be adapted for use with a modular diaphragm-sensing pressure-reducing regulating valve arrangement and a modular diaphragm-sensing back-pressure regulating valve arrangement.

[0097] In Figure 14 the illustrated embodiment, the leaf spring-loading mechanism 1250 includes a leaf spring housing 1251 that is assembled with the valve body (e.g., by mounting screws) to define a leaf spring chamber 1252, and includes a pressurized port 1253 for supplying pressurized fluid (e.g., from an auxiliary pressure regulator) to the leaf spring chamber at a set pressure to apply a corresponding load force to a diaphragm 1281 of a diaphragm sensing mechanism 1280 (e.g., Figure 8 the pressure-reducing regulator diaphragm sensing mechanism 580 of Figure 9 or the back-pressure regulator diaphragm sensing mechanism 680 of

[0098] A piston sensing bellows loading arrangement for remote adjustability, such as for regulator pressure setting, can be adapted to be used with a modular piston sensing pressure reducing regulator arrangement and a modular piston sensing back pressure regulator arrangement.

[0099] In Figure 15 the illustrated embodiment, the bellows loading mechanism 1350 includes an upper bellows housing shell member 1351-1 and a lower bellows housing shell member 1351-2 that are assembled to the valve body (e.g., by mounting screws) to define a bellows chamber 1352, and a bellows loading diaphragm 1359 having an outer perimeter that is captured between the upper and lower shell members, wherein a diaphragm screw 1354 is installed through a central opening in the bellows loading diaphragm and positioned to engage an upper end portion 1386 of a sensing element support member 1382 (e.g., Figures 11 to 12 the piston members 982, 1082). In the illustrated example, support plates 1355-1, 1355-2 are secured to the diaphragm screw 1354 above and below the bellows loading diaphragm 1359 by nuts 1356 to provide additional support for the diaphragm. The upper bellows housing shell member 1351-1 includes a pressurization port 1353 for supplying a pressurized fluid (e.g., from an auxiliary pressure regulator) to the bellows chamber at a set pressure to apply a corresponding loading force to the bellows loading diaphragm 1359 to move the diaphragm screw 1354 against a piston member 1382 of a piston sensing mechanism 1380 (e.g., Figure 11 the pressure reducing regulator piston sensing mechanism 980 or Figure 12 the back pressure regulator diaphragm sensing mechanism 1080).

[0100] The pressure regulator can be provided with a self-discharge feature that is configured to reduce the outlet pressure in the pressure reducing regulator when the regulator set point is decreased and no flow passes through the regulator. The self-discharge feature can include a discharge passage through a sensing element (e.g., a diaphragm screw through a diaphragm sensing element or a piston member through a piston sensing element) and a discharge passage through the regulator valve body. In accordance with one aspect of the present disclosure, in combination with the use of a discharge type sensing element, a discharge adapter block or plate can be assembled to the regulator valve body to provide the self-discharge feature.

[0101] In Figure 16In the illustrated embodiment, the bleed diaphragm sensing mechanism 1480 includes a flat, flexible material disk (e.g., elastomer, plastic, or metal suitable for the system fluid) to form a diaphragm 1481 having an outer perimeter clamped or fixed between opposing surfaces of the valve body housing block 1415 and a bleed adapter block 1490 mounted, for example, by a threaded screw arrangement, between the valve body housing block and a loading mechanism housing 1451 (e.g., spring housing or Belleville spring housing). As shown, the bleed diaphragm sensing mechanism 1480 may include a bleed diaphragm screw 1482 mounted through a central opening in the diaphragm 1481, the bleed diaphragm screw including a bleed passage 1482-1 extending from the lower end face of the diaphragm to an intermediate portion of the diaphragm, aligned with a cavity 1491 in the bleed adapter block 1490 and in fluid communication with a bleed port 1492 in the bleed adapter block 1490. The bleed port 1492 may be threaded for connection to a fluid line to receive and / or analyze the bled fluid. The bleed diaphragm screw 1482 may include a plastic (e.g., PEEK) pressure relief seat 1482-2 to facilitate sealing engagement with the upper lift rod 141 at a pressure below the set point of the regulator.

[0102] In Figure 17 In the illustrated embodiment, the bleed piston sensing mechanism 1580 includes a piston member 1582 received in a central piston bore 1584 of a piston adapter block or plate 1583, with the upper portion of the piston member received through a central bore of a bleed adapter block 1590. The piston adapter plate 1583 and the bleed adapter block 1590 are secured together, for example, by a threaded screw arrangement, between a valve body housing block 1515 and a loading mechanism housing 1551 (e.g., spring housing or Belleville spring housing). As shown, the bleed piston sensing mechanism 1580 may include a bleed piston member 1582 having a bleed passage 1582-1 mounted and extending from the lower end face of the piston member to a middle portion of the piston member, aligned with a cavity 1591 in the bleed adapter block 1590 and in fluid communication with a bleed port 1592 in the bleed adapter block. The bleed port 1592 may be threaded for connection to a fluid line to receive and / or analyze the bled fluid. The bleed diaphragm screw 1582 may include a plastic (e.g., PEEK) pressure relief seat 1582-2 to facilitate sealing engagement with the upper lift rod 141 at a pressure below the set point of the regulator.

[0103] For many of the exemplary features and embodiments described herein, the regulator components can be adapted for use in multiple regulator arrangements, e.g., to reduce the number of components required to construct multiple regulators. For example, as described herein, a modular regulator valve body housing can be configured for use in both a pressure reducing regulator assembly and a back pressure regulator assembly (e.g., by installing a guide ring in the valve body cavity to support the upper lift rod of the pressure reducing regulator valve arrangement and by selectively orienting the seat bracket to provide a downward-facing seat seal for the pressure reducing regulator assembly and an upward-facing seat seal for the back pressure regulator assembly). Additionally or alternatively, the modular regulator valve body housing can be configured for use with a diaphragm sensing arrangement and a piston sensing arrangement (e.g., by assembling a piston adapter block or plate with the valve body housing to accommodate the piston sensing arrangement). Additionally or alternatively, the modular regulator valve body housing can be configured to function as a non-discharge assembly and a self-discharge assembly (e.g., by assembling a discharge adapter block with the valve body housing and installing a discharge piston member / diaphragm screw to provide a self-discharge function).

[0104] Figures 18 to 20 An exemplary piston sensing, self-discharging, spring-loaded pressure reducing regulator assembly 2000-1 is shown and includes: a valve body module 2100 having a valve body housing block 2110 and a plug 2120 that holds or accommodates a pressure reducing lift member 2130 and seat 2140 arrangement; a piston module 2200 that includes a piston adapter block 2210 that holds or accommodates a piston sensing member 2220 that engages the lift member; a self-discharge module 2300 that includes a discharge adapter block 2310 that defines a discharge port 2311 that is in fluid communication with a discharge channel 2221 in the piston sensing member; and a spring-loaded module 2400 that includes a loading block 2410 that holds a spring-loading mechanism (e.g., Figure 13 the spring-loading mechanism shown and described above). The modular component blocks 2100, 2200, 2300, 2400 are provided with aligned holes 2109, 2209, 2309, 2409 (e.g., spaced around the outer perimeter as shown) to receive elongated bolts 2009 that secure the blocks together as an assembly.

[0105] To accommodate different modular arrangements that exclude one or both of the piston module 2200 and the self-discharge module, a consistent mating / sealing arrangement can be provided between the stacked module blocks 2110, 2210, 2310, 2410 such that the regulator assembly can be converted to or otherwise provided as:

[0106] ● Diaphragm sensing discharge assembly 2000-2, by omitting the piston module 2200 and directly assembling the valve body housing block 2110 to the discharge adapter block 2310 (where the diaphragm sub-assembly 2250 is installed in the cavity defined between the valve body housing block and the discharge adapter block), as Figure 21 shown;

[0107] ● Piston sensing non-discharge assembly 2000-3, by omitting the discharge module 2300 and directly assembling the piston adapter block 2210 to the loading block 2410, as Figure 22 shown; or

[0108] ● Diaphragm sensing non-discharge assembly 2000-4, by omitting both the piston module 2200 and the discharge module 2300 and directly assembling the valve body housing block 2110 to the loading block 2410 (where the diaphragm sub-assembly 2250 is installed in the cavity defined between the valve body housing block and the discharge adapter block), as Figure 23 shown.

[0109] A variety of consistent first block assembly interfaces and second block assembly interfaces are available for consistent mating and sealed engagement between adjacent blocks. In one exemplary embodiment, as Figure 19 shown, the valve body housing block 2110, the piston adapter block 2210, and the discharge adapter block 2310 are each provided with a first assembly interface that includes uniformly sized upper ring-drilled seal grooves 2115, 2215, 2315 or grooves 2214, 2314 recessed from the upper end face counterbores 2114 to accommodate the ring gasket seals 2106, 2206, 2306. The piston adapter block 2210, the discharge adapter block 2310, and the loading block 2410 each include corresponding second assembly interfaces that include uniformly sized lower ring shoulders 2217 or ribs 2317, 2417 that are received in the corresponding counterbores 2114 or grooves 2214, 2314 to sealably compress the ring gasket seals 2106, 2206, 2306.

[0110] As Figure 21 and Figure 23 shown, the diaphragm sensing assemblies 2000-2, 2000-4 may include a diaphragm 2251 that has an outer periphery (e.g., a flange) 2256 that is compressed between the ring-drilled seal groove and the boss / rib (e.g., in combination with or in place of the gasket seal 2106) to achieve a seal between the valve body housing block 2110 and the diaphragm 2251 and between the valve body housing block and the adjacent discharge adapter block (in Figure 21 ), or the loading block (in Figure 23 ).

[0111] Additionally, alternative loading modules (e.g., asFigure 14 the shrapnel loading module shown, or as Figure 9 , Figure 10 and Figure 15 the highly sensitive spring / shrapnel loading module shown) may be provided with a similar lower annular boss or rib for assembly with the same valve body housing 2110, piston adapter 2210, and discharge adapter block 2310.

[0112] Referring to Figure 23 , the exemplary pressure reducing regulator valve body module 2100 includes a guide ring 2170 (e.g., similar to the aforementioned guide ring 170), which is installed in the enlarged upper recess 2118 of the valve body housing block 2110 to closely receive the upper lift rod of the pressure reducing lift member 2130. As Figure 24 shown, in order to convert the regulator assembly or otherwise provide it as a back pressure regulator assembly 2000-4a, the guide ring 2170 can be removed so that the enlarged upper recess 2118 of the valve body housing block 2110 can accommodate the larger upper lift rod of the back pressure lift member 2130a that is combined and installed with the back pressure seat 2140a and the diaphragm back pressure sub-assembly 2250a.

[0113] As shown in the figure, Figures 18 to 24 the modular regulator assembly may include Figures 3 to 17 the components and features more fully described in the above description of the embodiments of

[0114] The inventive aspects have been described with reference to exemplary embodiments. Modifications and alterations will occur to others upon reading and understanding this specification. It is intended to embrace all such modifications and alterations as long as they fall within the scope of the appended claims or their equivalents.

Claims

1. A valve assembly, the valve assembly comprising: A valve body, the valve body comprising: A body housing that defines a first end port, a second end port, and a central cavity extending from a bottom end of the body housing to a top end of the body housing; and A body plug that is assembled with the central cavity of the body housing and defines a flow path between the first end port and the second end port; A seat carrier subassembly disposed in the body housing and fixed between an end face of the body plug and a counterbore in the central cavity, the seat carrier subassembly including a first annular member and a second annular member, the first annular member and the second annular member being assembled on an O-ring seal, wherein a portion of the O-ring seal is exposed in an inner diameter gap between inner edge portions of the first annular member and the second annular member to define a seat seal; and A lifter that is assembled with the valve body and is axially movable in the central cavity of the body housing between a closed position and an open position, in the closed position, a radially extending sealing surface of the lifter seals on the seat seal to prevent fluid from flowing through an axially extending portion of the flow path, in the open position, the sealing surface of the lifter is axially separated from the seat seal to permit fluid to flow between the first end port and the second end port.

2. The valve assembly according to claim 1, wherein the first annular member and the second annular member are axially compressible on the O-ring seal to squeeze a seat seal portion of the O-ring seal through the inner diameter gap between the first annular member and the second annular member.

3. The valve assembly according to claim 1, wherein the first annular member includes a radially inwardly extending flange that defines an inner counterbore and an axially upwardly extending flange that defines an outer counterbore, and the second annular member includes an outer peripheral portion seated in the outer counterbore of the first annular member and an axially downwardly extending flange that extends toward the radially inwardly extending flange of the first annular member to define an annular cavity and the inner diameter gap for the O-ring seal.

4. The valve assembly according to claim 1, wherein the seat carrier subassembly is fixed between an upper end face of the body plug and a body counterbore in the central cavity of the body housing.

5. The valve assembly according to claim 4, wherein the seat carrier subassembly includes a gasket seal that is sealingly engaged with the body counterbore.

6. The valve assembly according to claim 1, wherein the valve assembly further includes an actuator that is assembled with the valve body for moving the lifter between the open position and the closed position.

7. The valve assembly according to claim 6, wherein the actuator comprises: A loading mechanism configured to bias the lifter toward one of the open position and the closed position; and a sensing mechanism that is in fluid communication with the first end port and is configured to move against the loading mechanism when the fluid pressure in the first end port exceeds a set pressure to permit the lifter to move to the other of the open position and the closed position.

8. The valve assembly of claim 1, wherein the sealing surface of the lifter is an upward-facing sealing surface.

9. The valve assembly of claim 1, wherein the sealing surface of the lifter is a downward-facing sealing surface.

10. A seat support frame assembly, the seat support frame assembly being for a valve, the seat support frame assembly comprising: A first annular member and a second annular member, the first annular member and the second annular member being assembled on an O-ring seal, wherein a portion of the O-ring seal is exposed in an inner diameter gap between the inner edge portions of the first annular member and the second annular member to define a seat seal.

11. The seat carrier subassembly of claim 10, wherein the first annular member and the second annular member are axially compressible on the O-ring seal to squeeze a seat seal portion of the O-ring seal through the inner diameter gap between the first annular member and the second annular member.

12. The seat carrier subassembly of claim 10, wherein the first annular member includes a radially inwardly extending flange that defines an inner counterbore and an axially upwardly extending flange that defines an outer counterbore, and the second annular member includes an outer peripheral portion that sits in the outer counterbore of the first annular member and an axially downwardly extending flange that extends toward the radially inwardly extending flange of the first annular member to define an annular cavity and the inner diameter gap for the O-ring seal.

13. The seat carrier subassembly of claim 10, wherein the seat seal faces a first side of the seat carrier subassembly.

14. The seat carrier subassembly of claim 13, wherein the seat carrier subassembly further includes a face seal O-ring disposed in an annular groove in the first side of the seat carrier subassembly.

15. The seat carrier subassembly of claim 13, wherein the seat carrier subassembly further includes a face seal O-ring disposed in an annular groove in a second side of the seat carrier subassembly opposite the first side.

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