Two-stage pressure regulator for compressed gas
By designing a two-stage pressure regulator, the pressure is adjusted using the spring bias force of the piston and seat assembly, combined with the safety pressure relief valve and exhaust port, the existing pressure regulators are solved by solving the problem of insufficient wear and adjustment accuracy under high pressure, achieving long-term stability and precise pressure adjustment of the components.
Patent Information
- Application Number
- CN202280102413.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2022-12-07
- Publication Date
- 2025-07-22
AI Technical Summary
Existing dual-stage pressure regulators are prone to wear and tear in high-pressure environments to cause component losses, and it is difficult to accurately adjust the pressure, affecting the long-term stability and efficiency of the equipment.
A two-stage pressure regulator is designed, including upstream and downstream piston and seat assembly, adjusting the piston position through spring biasing force, reducing the pressure from 700 bar to 50 bar and then to 10 bar, combining a safety pressure relief valve and exhaust port to reduce component wear and improve adjustment accuracy.
It effectively reduces component wear, improves the accuracy of pressure regulation and the long-term stability of the equipment, and ensures the reliability and safety of the pressure regulator in high-pressure environments.
Smart Images
Figure CN120359374A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to regulators, and more particularly to two-stage pressure regulators for compressing gases. BACKGROUND OF THE INVENTION
[0002] Pressure regulators are used to control the pressure of a fluid (such as a gas or a liquid) at a desired value. Some pressure regulators are two-stage regulators that include two regulators in series. The first of the regulators reduces the pressure of the fluid from a first level to a second level, and the second of the regulators reduces the pressure of the fluid from the second level to a third level. Some two-stage regulators include two safety valves, with each safety valve dedicated to a respective one of the regulators. The components of a two-stage regulator are often exposed to relatively large pressure and force levels, which over time results in an undesired amount of wear on those components. SUMMARY OF THE INVENTION
[0003] Disclosed herein is an example two-stage pressure regulator. The two-stage pressure regulator includes a body defining an inlet, an outlet, and a chamber extending between the inlet and the outlet. The chamber includes an inlet section, an intermediate section, and an outlet section. The body includes an upstream valve seat adjacent the inlet. The two-stage pressure regulator includes an upstream piston slidably positioned in the chamber adjacent the inlet to separate the inlet section of the chamber from the intermediate section. The upstream piston includes a first plug configured to engage the upstream valve seat in a first closed position. The first plug is configured to disengage from the upstream valve seat in a first open position to enable compressed gas to flow from the inlet section to the intermediate section. The two-stage pressure regulator includes a seat assembly received in the chamber and fixed to the body. The seat assembly includes a downstream valve seat. The two-stage pressure regulator includes a downstream piston slidably positioned in the chamber adjacent the inlet to separate the intermediate section of the chamber from the outlet section. The downstream piston includes a second plug configured to engage the downstream valve seat in a second closed position. The second plug is configured to disengage from the downstream valve seat in a second open position to enable the compressed gas to flow from the intermediate section to the outlet section. BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Figure 1 is a perspective view of an example pressure regulator in accordance with the teachings herein.
[0005] Figure 2 is Figure 1 a side view of the pressure regulator of
[0006] Figure 3 is a cross-sectional view of Figure 1 the pressure regulator of
[0007] Figure 4 is in an intermediate state Figure 1 Cross-sectional view of the pressure regulator along a second plane perpendicular to the first plane.
[0008] Figure 5 is Figure 1 Cross-sectional view of the second-stage piston of the pressure regulator.
[0009] Figure 6 is Figure 1 Cross-sectional view of the valve seat assembly.
[0010] Figure 7 is Figure 1 Cross-sectional view of the first-stage piston of the pressure regulator.
[0011] Figure 8 is in a closed state Figure 1 of the pressure regulator along Figure 4 the second plane.
[0012] Figure 9 is in a closed position Figure 7 of the second-stage piston along Figure 4 Expanded view of the cross-sectional view along the second plane.
[0013] Figure 10 is when Figure 7 the second-stage piston is in the closed position, Figure 5 the second-stage piston and Figure 6 Another expanded view of the cross-sectional view of the valve seat assembly.
[0014] Figure 11 is in an open position Figure 7 of the second-stage piston along Figure 4 the second plane. Expanded view of the cross-sectional view.
[0015] Figure 12 is in a closed position Figure 7 of the first-stage piston along Figure 4 the second plane. Expanded cross-sectional view.
[0016] Figure 13 is in an open position Figure 7 of the first-stage piston along Figure 4 the second plane. Expanded cross-sectional view.
[0017] Figure 14A is Figure 1 Front view of the safety relief valve of the pressure regulator.
[0018] Figure 14B is Figure 14A Cross-sectional view of the safety relief valve.
[0019] Figures 15A to 15D Depict opening Figure 14A and 14B the sequence of the safety relief valve.
[0020] Figure 16 is a cross-sectional view of a Figure 1 pressure regulator with a sealed cover. Detailed implementation mode
[0021] The following description describes, illustrates, and exemplifies one or more embodiments of the present invention according to its principles. This description is provided not to limit the present invention to the embodiments described herein, but to explain and teach the principles of the present invention so that those of ordinary skill in the art can understand these principles and, upon understanding these principles, be able to apply them not only to practice the embodiments described herein, but also to practice other embodiments that can be conceived according to these principles. This specification is intended as a whole and is to be interpreted in accordance with the principles of the present invention taught herein and understood by those of ordinary skill in the art.
[0022] The scope of the present invention is intended to cover all such embodiments that may fall within the scope of the appended claims, either literally or under the doctrine of equivalents. The description in the specification is not intended to limit the claims or the exemplary embodiments of the claimed invention. Features described in the specification but not recited in the claims are not intended to limit the claims.
[0023] It should be noted that in the description and the drawings, the same or substantially similar elements may be labeled with the same reference numerals. However, sometimes these elements may be labeled with different numerals, for example, for the sake of more clear description, for example. Additionally, the drawings set forth herein are not necessarily drawn to scale, and in some instances, the scale may be exaggerated to more clearly depict certain features. This labeling and drawing convention do not necessarily imply a potential substantial purpose.
[0024] Some features may be described using relative terms, such as top, bottom, vertical, right, left, etc. It should be understood that such relative terms are only for reference with respect to the drawings. These relative terms do not mean to limit the disclosed embodiments.
[0025] The exemplary pressure regulator disclosed herein includes two stages. The first stage is configured to reduce the pressure of a compressed gas (e.g., hydrogen, nitrogen, oxygen, argon, compressed natural gas, compressed air, etc.) from an upstream pressure to an intermediate pressure, and the second stage is configured to further reduce the intermediate pressure to a downstream pressure (e.g., about 10 bar). The first stage is configured to significantly reduce the fluid pressure (e.g., from 700 bar to about 50 bar) so that the second stage can reduce the fluid pressure in a more precise and accurate manner (e.g., to about 10 bar).
[0026] In some instances, the first stage is configured to significantly reduce fluid pressure to protect downstream components from an undesired degree of wear. In some instances, the pressure regulator includes a spring for the piston of the second stage. The operator can adjust the position of this spring to adjust the final fluid pressure when the fluid exits the pressure regulator. In some instances, the pressure regulator includes a spring for the valve seat of the second stage. This spring is configured to compress when the piston of the second stage engages the valve seat to reduce wear of the valve seat over time.
[0027] In some instances, the pressure regulator includes a single exhaust port configured to discharge fluid that has escaped from multiple different sections of the pressure regulator (e.g., an inlet section, an outlet section, an intermediate section). Additionally, in some instances, the pressure regulator includes a safety relief valve configured to open when the pressure in the outlet section is greater than a predefined pressure threshold and / or when the operator manually operates the safety relief valve.
[0028] Turning to the figure, Figures 1 to 2 depicts an exterior of an example of a pressure regulator 100 as disclosed herein. The pressure regulator 100 includes a body 110. The body 110 includes a main body 112, an inlet body 160, and an outlet body 170. As disclosed in more detail below, the body 110 defines a chamber 120 ( Figures 3 to 4 and 8) that houses a flow control assembly to control the flow of a compressed gas, such as hydrogen, through the body 110.
[0029] The inlet body 160 is coupled to a first end (also referred to as the “inlet end” and “upstream end”) of the main body 112 and defines an inlet 140 ( Figures 3 to 4 and 12 to 13) of the chamber 120. For example, the inlet body 160 includes threads (e.g., Figure 3 threads 162) that are threadedly received by threads (e.g., internal threads) of the main body 112 to be threadedly coupled to the first end of the main body 112. The pressure regulator 100 includes one or more threaded posts 150 positioned along the first end of the main body 112. In the illustrated example, the pressure regulator 100 includes three threaded posts 150. As disclosed in more detail below, the threaded posts 150 extend into the main body 112 and are threadedly received by the main body 112 to adjust the biasing force of a spring 520 ( Figures 3 to 4 , 9, and 11), which in turn adjusts the operation of one of the two stages of the pressure regulator 100.
[0030] The outlet body 170 is coupled to the second end (also referred to as the "outlet end" and "downstream end") of the main body 112 and defines an outlet 145 of the chamber 120. The second end of the main body 112 is opposite the first end such that the outlet body 170 is opposite the inlet body 160. The body 110 includes one or more fasteners 172 to couple the outlet body 170 to the second end of the main body 112.
[0031] In the illustrated example, the body 110 includes an exhaust fitting 600 coupled to the main body 112. As disclosed in more detail below, the exhaust fitting 600 defines an exhaust port 650 that is configured to vent gases (such as hydrogen) that may have leaked from the chamber 120 of the body 110. For example, the exhaust port 650 is configured to vent highly flammable hydrogen into an exhaust system for safe dissipation. The pressure regulator 100 also includes a safety relief valve 700 coupled to the outlet body 170 of the body 110. The safety relief valve 700 is configured to open when the downstream pressure increases above a predetermined threshold. When opened, the safety relief valve 700 directs gases (such as hydrogen) from the outlet 145 to the exhaust port 650 to reduce the downstream pressure by dissipating some of the gases (such as hydrogen) to the environment.
[0032] Figures 3 to 4 A cross-sectional view of the pressure regulator 100 is depicted. Specifically, Figure 3 is a cross-sectional view of the pressure regulator 100 along a first plane when the pressure regulator 100 is in the open state, and Figure 4 is a cross-sectional view of the pressure regulator 100 along a second plane perpendicular to the first plane when the pressure regulator 100 is in the intermediate state. When the pressure regulator 100 is in the open state, the piston 200 is in a first open position and the piston 400 is in a second open position, and when the pressure regulator 100 is in the intermediate state, the piston 200 is in a first closed position and the piston 400 is in a second open position. The intermediate section 124 is defined by the piston 200, the seat assembly 300, and the body 110. More specifically, in the illustrated example, the intermediate section 124 is defined by the piston 200, the seat assembly 300, the valve seat 164 of the inlet body 160, and the inner wall 114 of the main body 112.
[0033] In the illustrated example, the body 110 defines a chamber 120. The body 110 defines an inlet 140 on a first side (also referred to as the "inlet side" and "upstream side") of the body 110 and an outlet 145 on a relative second side (also referred to as the "outlet side" and "downstream side") of the body 110. The chamber 120 extends between the inlet 140 and the outlet 145 and is fluidly connected to the inlet 140 and the outlet 145. The body 110 includes a main body 112 that defines the chamber 120.
[0034] The body 110 includes an inlet body 160 (also referred to as the "inlet-side body" and "upstream-side body"), the inlet body 160 being coupled to a first side of the main body 112 and defining an inlet 140 of the pressure regulator 100. As Figure 3 shown, the inlet body 160 is coupled to the first side of the main body 112 via threads 162. A seal 163 (e.g., an O-ring) extends between the inlet body 160 and the main body 112 and sealingly engages the inlet body 160 and the main body 112 to form a sealed connection therebetween. The inlet body 160 includes a valve seat 164 (also referred to as the "first valve seat", "first-stage valve seat", and "upstream valve seat") adjacent to the inlet 140, and defines chambers 166, 168 separated by the valve seat 164. The chamber 166 (also referred to as the "first inlet chamber") is configured to receive compressed gas, such as hydrogen, from a source, and the chamber 168 (also referred to as the "second inlet chamber") is configured to slidably receive a portion of the piston 200. When the plug 250 of the piston 200 disengages from the valve seat 164, the chamber 166 is in fluid communication with the chamber 168.
[0035] The body 110 includes an outlet body 170 (also referred to as the "outlet-side body" and "downstream-side body"), the outlet body 170 being coupled to a second side of the main body 112 and defining an outlet 145 of the pressure regulator 100. In the illustrated example, the outlet body 170 is coupled to the second side of the main body 112 via a fastener 172. For example, the fastener 172 is a threaded fastener extending through the outlet body 170 and threadedly received by the main body 112 to fasten the outlet body 170 to the main body 112. A seal 173 (e.g., a gasket) extends between the outlet body 170 and the main body 112 and sealingly engages the outlet body 170 and the main body 112 to form a sealed connection therebetween. As Figure 3 shown, the outlet body 170 defines a chamber 174 (also referred to as the "outlet chamber") configured to be in fluid communication and provide compressed gas (e.g., hydrogen) downstream of the pressure regulator 100. The outlet body 170 also includes an inner wall 178 that extends into the chamber 120 and engages an outer wall 118 of the main body 112.
[0036] The pressure regulator 100 of the illustrated example is a two-stage pressure regulator. The pressure regulator 100 includes a piston 200, a seat assembly 300, and a piston 400 housed in a chamber 120. The piston 200 (also referred to as the "first piston", "first-stage piston", and "upstream piston") is configured to slidably engage a valve seat 164 of the body 110 to operate the first stage of the two-stage pressure regulator. The piston 400 (also referred to as the "second piston", "second-stage piston", and "downstream piston") is configured to slidably engage a valve seat 340 of the seat assembly 300 ( Figure 6 ) to operate the second stage of the two-stage pressure regulator.
[0037] As disclosed in more detail below, the piston 400 of the second stage is configured to open before the piston 200 of the first stage. The first stage is configured to reduce the pressure of a compressed gas (such as hydrogen) from an upstream pressure (e.g., about 700 bar) to an intermediate pressure (e.g., about 50 bar), and the second stage is configured to further reduce the intermediate pressure to a downstream pressure (e.g., about 10 bar). The first stage is configured to significantly reduce the fluid pressure (e.g., from 700 bar to about 10 bar) so that the second stage can reduce the fluid pressure in a more precise and accurate manner (e.g., reduce to about 10 bar).
[0038] As Figures 3 to 4 shown, the seat assembly 300 is housed in the chamber 120 and is fixed to the body 110. The seat assembly 300 is fixed to the inner wall 114 of the main body 112 that at least partially defines the chamber 120. In the illustrated example, the seat assembly 300 is fixed to the inner wall 114 via threads 116. The piston 200 is slidably positioned in the chamber 120, adjacent to the inlet 140, and between the seat assembly 300 and the inlet body 160. The piston 400 is slidably positioned in the chamber 120, adjacent to the outlet 145, and between the seat assembly 300 and the outlet body 170. The piston 200 is configured to slide between the seat assembly 300 and the inlet body 160 along the longitudinal axis of the body 110 to open and close the first stage of the operation of the pressure regulator 100, and the piston 400 is configured to slide between the seat assembly 300 and the outlet body 170 along the longitudinal axis of the body 110 to open and close the second stage of the operation of the pressure regulator 100.
[0039] The pressure regulator 100 includes a spring 510 (also referred to as the "first spring" and "first-stage spring") for biasing the piston 200 toward a corresponding open position and a spring 520 (also referred to as the "second spring" and "second-stage spring") for biasing the piston 400 toward a corresponding open position. In the illustrated example, the spring 510 extends between the piston 200 and the inlet body 160 within the chamber 120 of the body 110 and engages the piston 200 and the inlet body 160 to bias the piston 200 toward the corresponding open position. The spring 520 is received within the chamber 120 and is radially positioned between the inner wall 114 and the outer wall 118 of the main body 112 of the body 110. The spring 520 extends between the piston 400 and the main body 112 of the body 110 and engages the piston 400 and the main body 112 of the body 110 to bias the piston 400 toward the corresponding open position.
[0040] The body 110 includes a main body 112, an inlet body 160, and an outlet body 170. The chamber 120 is defined by the body 110 and is divided into a plurality of sections. As Figures 3 to 4 shown, the chamber 120 includes an inlet section 122, an intermediate section 124, and an outlet section 126. The inlet section 122 extends from the inlet 140 to the valve seat 164, the intermediate section 124 extends from the valve seat 164 to the valve seat 340, and the outlet section 126 extends from the valve seat 340 to the outlet 145. The inlet section 122 is defined by the body 110 and the piston 200. More specifically, in the illustrated example, the inlet section 122 is defined by the inlet body 160 of the body 110 and the plug 250 of the piston 200 ( Figure 7 ). The intermediate section 124 is defined by the piston 200, the seat assembly 300, and the body 110. More specifically, in the illustrated example, the intermediate section 124 is defined by the piston 200, the seat assembly 300, the valve seat 164 of the inlet body 160, and the inner wall 114 of the main body 112. The outlet section 126 is defined by the piston 400 and the body 110. More specifically, in the illustrated example, the outlet section 126 is defined by the piston 400 and the outlet body 170.
[0041] The inlet section 122 and the intermediate section 124 are in fluid communication with each other based on the position of the piston 200. If the piston 200 is in a corresponding closed position (also referred to as the "first closed position" and "first-stage closed position"), the inlet section 122 and the intermediate section 124 are fluidly separated from each other via the piston 200. If the piston 200 is in a corresponding open position (also referred to as the "first open position" and "first-stage open position"), then the inlet section 122 and the intermediate section 124 are fluidly connected to each other such that compressed gas can flow from the inlet section 122 into the intermediate section 124.
[0042] The outlet section 126 and the intermediate section 124 are in fluid communication with each other based on the position of the piston 400. If the piston 400 is in the respective closed positions (also referred to as the "second closed position" and the "second stage closed position"), the outlet section 126 and the intermediate section 124 are fluidly separated from each other via the piston 400. If the piston 400 is in the respective open positions (also referred to as the "second open position" and the "second stage open position"), the outlet section 126 and the intermediate section 124 are fluidly connected to each other such that compressed gas can flow from the intermediate section 124 into the outlet section 126.
[0043] The chamber 120 of the illustrated example also includes an exhaust section 128. The exhaust section 128 is defined by the body 110 and the piston 400. More specifically, in the illustrated example, the exhaust section 128 is defined by the inner wall 114 and the outer wall 118 of the main body 112, the outlet body 170, and the piston 400. The body 110 also defines an exhaust port 650 that is in fluid communication with the exhaust section 128. The exhaust port 650 is formed by the exhaust port 119 and / or the exhaust fitting 600. As Figure 4 illustrated, the outer wall 118 of the main body 112 defines the exhaust port 119, and the exhaust fitting 600 of the body 110 is sealingly positioned in the exhaust port 119. The exhaust port 119, in turn, defines the exhaust port 650 for the exhaust section 128 of the chamber 120. In other examples, the pressure regulator 100 does not include the exhaust fitting 600 such that the exhaust port 119 defines the exhaust port 650 for the exhaust section 128.
[0044] The exhaust section 128 is fluidly connected to the exhaust passages 132, 134, 136. The exhaust port 650, the exhaust section 128, and the exhaust passages 132, 134, 136 are arranged and fluidly connected to each other such that the exhaust port 650 can discharge any fluid that may have leaked from multiple different sections of the chamber 120. That is, the pressure regulator 100 of the illustrated example includes only one exhaust port 650 that can safely discharge fluid that may have leaked from multiple different source points.
[0045] The exhaust passage 132 (also referred to as the "outlet exhaust passage") is defined by the main body 112 of the body 110. The exhaust passage 132 extends from the exhaust section 128 to a portion of the inlet body 160 between the threads 162 and the seal 163. Although the threads 162 and the seal 163 are configured to form a sealed connection between the inlet body 160 and the main body 112, the exhaust passage 132 is configured to direct any fluid that may have leaked between the connections to the exhaust section 128 and then out through the exhaust port 165 to the environment for safe dissipation.
[0046] The exhaust passage 134 (also referred to as the "intermediate exhaust passage") is defined by the inner wall 114 of the main body 112. The exhaust passage 134 extends from the exhaust section 128 to adjacent the seat assembly 300 of the chamber 120 and is located in a portion between the seal 163, the seal 226 ( Figure 7 ) and the seal 236 ( Figure 7 ). Although the seal 163 is configured to form a sealed connection between the inlet body 160 and the main body 112, and the seals 226, 236 are configured to form a sealed connection between the seat assembly 300 and the body 110, the exhaust passage 134 is configured to direct any fluid that may have leaked between these connections to the exhaust section 128 and then discharged through the exhaust port 165 to the environment for safe dissipation.
[0047] The exhaust passage 136 (also referred to as the "exit exhaust passage") is defined by the outlet body 170 and the outer wall 118 of the main body 112. The exhaust passage 136 extends from the exhaust section 128 to (1) the safety relief valve 700 and (2) the seal 173 located between the outlet body 170 and the main body 112. Although the safety relief valve 700 and the seal 173 are configured to form a sealed connection with the outlet body 170, the exhaust passage 136 is configured to direct any fluid that may have leaked into the exhaust section 128 and then discharged through the exhaust port 165 to the environment for safe dissipation.
[0048] As Figure 4 shown, the safety relief valve 700 is partially received in the valve chamber 175. The outlet body 170 defines the valve chamber 175, the relief passage 176, and the exhaust passage 136 (also referred to as the "exit exhaust passage"). The valve chamber 175 is connected to both the relief passage 176 and the exhaust passage 136. When the outlet body 170 is coupled to the main body 112, the relief passage 176 is fluidly connected to the outlet section 126 of the chamber 120, and the exhaust passage 136 is fluidly connected to the exhaust section 128 of the chamber 120. As disclosed in more detail below, when the safety relief valve 700 is in the closed position, the safety relief valve 700 fluidly disconnects the exhaust passage 136 from the exhaust section 128, thereby preventing compressed gas in the outlet section 126 from entering the exhaust section 128. When the safety relief valve 700 is in the closed position, the safety relief valve 700 fluidly connects the exhaust passage 136 and the exhaust section 128 via the valve chamber 175 to allow compressed gas to flow from the outlet section 126 to the exhaust section 128. The safety relief valve 700 is configured to open when the pressure in the outlet section 126 is greater than a predetermined threshold. By opening and directing some compressed gas into the exhaust section 128 and discharging it through the exhaust port 650, the safety relief valve 700 can reduce the downstream pressure to less than the predetermined threshold.
[0049] The outlet body 170 includes a sensor chamber 177 for housing a sensor configured to monitor the pressure of compressed gas in the outlet section 126 of the chamber 120. Before inserting the pressure sensor into the sensor chamber 177, a passage (e.g., via drilling) is formed in the outlet body 170 to connect the sensor chamber 177 to the outlet section 126 so that the pressure sensor can monitor the pressure of the compressed gas in the outlet section 126.
[0050] Figure 5 is a cross-sectional view of a piston 400 that includes a piston body 410. The piston body 410 (also referred to as the “second piston body,” “second-stage piston body,” and “downstream piston body”) includes sections 420, 430 integrally formed together. Section 420 (also referred to as the “first section”) is hollow, has a substantially cylindrical shape, and is adjacent to the first end of the piston body 410. Section 430 is hollow, has a substantially cylindrical shape, and is adjacent to the opposite second end of the piston body 410. The piston body 410 defines a flow path 440 that extends along the longitudinal axis of the piston body 410. The flow path 440 extends the length of section 420 and the length of section 430. The flow path 440, the chamber 174 of the outlet body 170, the pressure relief path 176, and the chamber formed by the inner wall 178 of the outlet body 170 form the outlet section 126 of the chamber 120.
[0051] The piston 400 includes a plug 450 (also referred to as the “second plug,” “second-stage plug,” and “downstream plug”). In the illustrated example, the piston body 410 defines the plug 450. Specifically, the plug 450 is defined at the distal end of section 420 of the piston body 410. The plug 450 has a diameter 452 and a corresponding cross-sectional area. When the piston 400 transitions between the second closed position and the second open position, the plug 450 is configured to sealingly engage and disengage from the valve seat 340 of the seat assembly 300, respectively.
[0052] Section 430 has a diameter 432 and a corresponding cross-sectional area. The outer radial end of section 430 defines a groove 434 in which a seal 436 and a gasket 438 are received. The seal 436 (e.g., an O-ring) is configured to form a sealed connection between the piston 400 and the outlet body 170. As Figure 9 shown, the seal 436 sealingly engages section 430 of the piston 400 and the inner wall 178 of the outlet body 170 to form a sealed connection. Return Figure 5 , the gasket 438 is configured to engage the seal 436 to maintain the position of the seal 436 within the groove 434. Section 430 of the illustrated example also forms a spring seat 460. The spring seat 460 is configured such that the end of a spring 520 ( Figure 9 ) can firmly engage the piston 400, such that the spring 520 can bias the piston 400 to the second open position.
[0053] Figure 6 is a cross-sectional view of a seat assembly 300 that includes a body 310 (also referred to as the "seat assembly body" and the "seat body"). The body 310 includes sections 320, 330 integrally formed together. The body 310 is fixed to the body 110 via threads 332 positioned on the outer radial surface of the section 330. The section 320 (also referred to as the "first section") is hollow, has a substantially cylindrical shape, and is positioned adjacent the first end 312 of the body 310. The section 330 (also referred to as the "second section") is hollow, has a substantially cylindrical shape, and is positioned adjacent the second end 314 of the body 310.
[0054] The section 320 defines a seat chamber 322 in which a valve seat 340 of the seat assembly 300 is securely received. In the illustrated example, the valve seat 340 is a seat disc. The seat assembly 300 also includes a spring 342 (also referred to as the "seat spring"), a spring bracket 344, and a spring plug 346 received in the seat chamber 322. The valve seat 340 (also referred to as the "second valve seat", the "second stage valve seat", and the "downstream valve seat") is positioned adjacent the proximal end of the seat chamber 322 of the section 330. The spring bracket 344 engages the spring 342, and the spring plug 346 is positioned adjacent the distal end of the seat chamber 322. The spring 342 extends between and engages the spring bracket 344 and the spring plug 346 to firmly press the valve seat 340 in place at the proximal end of the seat chamber 322.
[0055] In some examples, the plug 450 of the piston 400 may suddenly close, and then the edge of the plug 450 may punch the valve seat 340. Figure 10 is an enlarged cross-sectional view of the plug 450 engaging the valve seat 340. When this occurs, the spring 342 compresses and enables the valve seat 340 to move in the direction toward the inlet 140, thereby reducing the risk of wear and / or breakage of the valve seat 340 that may otherwise occur over time if the position of the valve seat 340 is fixed. When the piston 400 subsequently transitions back to the second open position, the spring 342 is configured to stretch to push the valve seat 340 back toward the outlet 145.
[0056] Return Figure 6 , the body 310 of the seat assembly 300 defines a flow path 350. In the illustrated example, the section 330 and a portion of the section 320 define the flow path 350. The flow path 350 extends along the longitudinal axis of the body 310 between the valve seat 340 and an outlet 354 of the flow path 350. The body 310 defines an outlet 354 at the second end 314 and an inlet 352 adjacent the valve seat 340. In the illustrated example, the inlet 352 is formed by one or more holes defined by the body 310.
[0057] The intermediate section 124 of the chamber 120 is partially formed by the outer surface of the section 320 and the adjacent portion of the inner wall 114 of the main body 112, such that when the compressed gas is in the intermediate section 124 of the chamber 120, it flows around the outer surface of the section 320 of the body 310. When the plug 450 of the piston 400 engages the valve seat 340 in the second closed position, the piston 400 covers the inlet 352 to fluidly disconnect the intermediate section from the outlet section 126. In contrast, when the plug 450 of the piston 400 disengages the valve seat 340 in the second open position, the inlet 352 is at least partially uncovered by the piston 400 to fluidly connect the intermediate section to the outlet section 126.
[0058] As Figures 3 to 4 clearly shown in FIGS. 6 and 8, the first end 312 and / or a portion of the section 320 of the body 310 is received by an opening (e.g., Figure 7 the outlet 248 of the piston 200) of the piston 200 such that the seat assembly 300 is partially nested within the piston 200. The second end 314 and / or a portion of the section 330 of the body 310 defines an opening (e.g., the outlet 354) that slidably receives the piston 400 such that the piston 400 is partially nested within the seat assembly 300. The piston 400 is partially nested within the seat assembly 300 and the seat assembly 300 is partially nested within the piston 200, such that the pressure regulator 100 has a compact footprint. Return Figure 6 , the seat assembly 300 includes a seal 362 (e.g., an O-ring), a gasket 364, and a retaining ring 366 positioned in the flow path 350. As Figure 10 most clearly shown in FIG., the seal 362 is configured to form a sealed connection between the seat assembly 300 and the piston 400. The gasket 364 and the retaining ring 366 are configured to hold the seal 362 in place.
[0059] Turning to Figure 7, depicting a cross-sectional view of the piston 200. The piston 200 includes a piston body 210 (also referred to as the "first piston body", "first-stage piston body", and "upstream piston body"). The piston body 210 includes sections 220, 230 integrally formed together. Section 220 (also referred to as the "first section") has a substantially cylindrical shape and is adjacent to the first end 212 of the piston body 210. Section 230 (also referred to as the "second section") is hollow, has a substantially cylindrical shape, and is adjacent to the opposite second end 214 of the piston body 210. The piston body 410 defines a flow path 240 extending between section 220 and section 230 along the longitudinal axis of the piston body 410. The flow path 240 extends the length of section 230 and a portion of the length of section 220. The flow path 240 includes a first section 242 defined by section 220 of the piston body 210 and a second section 244 defined by section 230 of the piston body 210. Section 220 of the piston body 210 defines an inlet 246 adjacent to the first end 212, and section 230 of the piston body 210 defines an outlet 248 located at the second end 214. In the illustrated example, the inlet 246 is formed by one or more holes defined by the piston body 210.
[0060] In Figures 3 to 4 , the piston 200 rotates relative to the seat assembly 300 such that the inlet 246 of the piston 200 extends radially in a direction perpendicular to the direction in which the outlet 354 of the seat assembly 300 extends. In Figures 8 to 13 , the piston 200 rotates relative to the seat assembly 300 such that the inlet 246 of the piston 200 extends radially in a direction parallel to the direction in which the outlet 354 of the seat assembly 300 extends.
[0061] Return Figure 7 , the piston 200 includes a plug 250 configured to engage and disengage from the valve seat 164, respectively, when the piston transitions between a first closed position and a first open position. The plug 250 (also referred to as the "first plug", "first-stage plug", and "upstream plug") is coupled to section 220 of the piston body 210 at the first end 212. The plug 250 has a diameter 251 and a corresponding cross-sectional area.
[0062] Section 220 of the piston body 210 includes flanges 222, 224 that define a groove 225. Flange 222 is positioned adjacent to the inlet 246 such that the inlet 246 is axially positioned between the plug 250 and flange 222. Flange 222 has a diameter 223 and a corresponding cross-sectional area. A seal 226 (e.g., an O-ring) is positioned in the groove 225 and, as most clearly shown in Figure 12 , is configured to sealingly engage section 220 and the inlet body 160 to form a sealed connection between the piston 200 and the inlet body 160.
[0063] A section 230 of the piston body 210 includes flanges 232, 234 that define a groove 235. The flange 234 is positioned adjacent to the second end 214 of the piston body 210. The second end 214 has a diameter 215 and a corresponding cross-sectional area. A seal 236 (e.g., an O-ring) and a washer 238 are positioned in the groove 235. As Figure 12 most clearly shown, the seal 236 is configured to sealingly engage the section 230 and the main body 112 to form a sealed connection between the piston 200 and the body 110. The washer 238 is configured to securely hold the seal 236 in the groove 235.
[0064] Figure 8 The pressure regulator 100 is depicted in a closed state. When the pressure regulator 100 is in the closed state, the piston 200 is in a first closed position and the piston 400 is in a second closed position. That is, when the pressure regulator 100 is in the closed state, (1) the plug 450 of the piston 400 sealingly engages the valve seat 340 of the seat assembly 300 to fluidly disconnect the intermediate section 124 from the outlet section 126, and (2) the plug 250 of the piston 200 sealingly engages the valve seat 164 of the body 110 to fluidly disconnect the inlet section 122 from the intermediate section 124.
[0065] As Figure 8 shown, the threaded post 150 extends into the main body and is threadedly received by the main body. The threaded post 150 is configured to adjust the biasing force of the spring 520. Subsequently, the threaded post 150 is configured to adjust the predetermined threshold when the piston 400 opens the second stage for the operation of the pressure regulator 100. For example, the end of the threaded post 150 extends into the exhaust section 128 of the chamber 120 and engages the end of the spring 520 opposite the spring seat 460. The positioning end of the threaded post 150 affects the positioning of the end of the spring 520, which affects the biasing force exerted by the spring 520 on the piston 400.
[0066] Figures 9 to 10 The second stage of the pressure regulator 100 in the second closed position is depicted. When the second stage is closed, the plug 450 of the piston 400 sealingly engages the valve seat 340 of the seat assembly 300. Subsequently, the outlet section 126 of the chamber 120 is fluidly disconnected from the intermediate section 124. Figure 11 The second stage of the pressure regulator 100 in the second open position is depicted. When the second stage is open, the plug 450 of the piston 400 is sealingly disengaged from the valve seat 340 of the seat assembly 300. Subsequently, the outlet section 126 is fluidly connected to the intermediate section 124.
[0067] The piston 400 is configured to be in a second closed position when a second closing force acting on the piston 400 is greater than an opposing second opening force acting on the piston 400. The piston 400 is configured to transition from the second closed position to the second open position when the second closing force decreases to a force less than the second opening force. The piston 400 is configured to be in the second open position when the second closing force is less than the second opening force. The second closing force is less than the second opening force when the pressure of the fluid in the outlet section 126 of the chamber 120 is less than a second predefined pressure threshold. The piston 400 is configured to transition from the second open position to the second closed position when the second closing force increases to a force greater than the second opening force.
[0068] In the illustrated example, the second closing force F 2C is equal to P D *A 2C . P D is equal to the pressure of the downstream fluid in the outlet section 126 of the pressure regulator 100. A 2C is equal to the surface area of the section 430 of the piston 400, as defined by its diameter 432 ( Figure 5 ).
[0069] The second opening force F 2O is equal to F 2S + F 2I . F 2S is equal to the biasing force of the spring 520 (also referred to as the "second biasing force" and "second stage biasing force"). F 2I is equal to P I *A 2O . P I is equal to the pressure of the fluid in the intermediate section 124 of the chamber 120. A 2O is equal to the surface area of the plug 450 of the piston 400, as defined by its diameter 452 ( Figure 5 ).
[0070] In the illustrated example, F 2I is negligible because the surface area of the plug 450 and the pressure in the intermediate section 124 are relatively small. Consequently, the second opening force F 2O is substantially equal to F 2S , i.e., the biasing force of the spring 520, such that the piston 400 is in the second closed position when F 2C > F 2S and in the second open position when F 2C < F 2S .
[0071] In operation, the second stage of the pressure regulator 100 is configured to open before the first stage of the pressure regulator 100. When the piston 400 is in the second open position and the piston 200 is in the first closed position, the pressure regulator 100 is in an intermediate state.
[0072] Figure 12 Depicts the first stage of the pressure regulator 100 in the first closed position. When the first stage is closed, the plug 250 of the piston 200 sealingly engages the valve seat 164 of the body 110. Subsequently, the intermediate section 124 of the chamber 120 is fluidly disconnected from the inlet section 122. Figure 13 Depicts the first stage of the pressure regulator 100 in the first open position. When the first stage is open, the plug 250 of the piston 200 is sealingly disengaged from the valve seat 164 of the body 110. Subsequently, the outlet section 126 is fluidly connected to the intermediate section 124.
[0073] In operation, the first stage of the pressure regulator 100 is configured to open only when the second stage has opened. When the piston 200 is in the first open position and the piston 400 is in the second open position, the pressure regulator 100 is in an open state, which enables compressed gas (e.g., hydrogen) to flow into the inlet 140; through the inlet section 122, intermediate section 124, and outlet section 126 of the chamber 120; and out through the outlet 145. The piston 200 is configured to be in the first closed position when the first closing force acting on the piston 200 is greater than the opposing first opening force acting on the piston 200. The piston 200 is configured to transition from the first closed position to the first open position when the first closing force decreases to a force less than the first opening force. The piston 200 is configured to be in the first open position when the first closing force is less than the first opening force. The piston 200 is configured to transition from the first open position to the first closed position when the first closing force increases to a force greater than the first opening force.
[0074] When the pressure of the fluid in the intermediate section 124 of the chamber 120 is less than the first predefined pressure threshold, the first closing force is less than the first opening force. When the first stage of the pressure regulator 100 opens, the pressure in the intermediate section 124 decreases. That is, when the piston 400 is in the first open position, the pressure in the intermediate section 124 decreases. Subsequently, after the first stage has been open for a period of time, the pressure in the intermediate section 124 becomes less than the first predefined pressure threshold.
[0075] In the illustrated example, the first closing force F 1C equals P I *A 1C . P I equals the pressure of the fluid in the intermediate section 124 of the pressure regulator 100. A 1CEqual to the surface area of the second end 214 of the piston body 210 of the piston 200, as defined by its diameter 215 ( Figure 7 ).
[0076] The first opening force F 1O Is equal to F 1S + F 1I + F 1P . F 1S Is equal to the biasing force of the spring 510 (also referred to as the "first biasing force" and "first-stage biasing force"). F 1I Is the intermediate opening force acting on the piston 200 in the intermediate section 124 of the chamber 120. F 1I Is equal to P I * A 1F . P I Is equal to the pressure of the fluid in the intermediate section 124 of the chamber 120. A 1F Is equal to the surface area of the section 220 of the piston body 210 of the seal engagement body 110, as defined by the diameter 223 of the flange 222 ( Figure 7 ). In the illustrated example, A 1C Is greater than A 1F , such that F 1C Is always greater than F 1I . F 1P Is the inlet side opening force, which acts on the plug 250 of the piston 200 in the inlet section 122 of the chamber 120. F 1P Is equal to P P * A 1P . P P Is equal to the pressure of the upstream fluid flowing into the inlet section 122 of the chamber 120. A 1P Is equal to the surface area of the plug 250 of the piston 200, as defined by the diameter 251 of the plug 250 ( Figure 7 ).
[0077] Go to Figures 14A to 14B , depicting the internal part of the safety relief valve 700. The safety relief valve 700 of the illustrated example includes a fixed body 720, a plug body 730, and a bolt 740. As Figure 8 Illustrated, the safety relief valve 700 also includes a cover 710, which is coupled to the outlet body 170 and covers the other parts of the safety relief valve 700.
[0078] Return Figures 14A to 14B , the fixed body 720 includes threads 722 for fixing the outlet body 170 coupled to the body 110. The fixed body 720 defines a hole 724 extending along the longitudinal axis of the safety relief valve 700. The chamber 726 is defined by the first end of the fixed body 720. The spring seat 728 is defined by the opposite second end of the fixed body 720.
[0079] The plug body 730 includes a thread 732 configured to threadedly receive a threaded end of a shaft 742 of a bolt 740 to couple the plug body 730 and the bolt 740. The plug body 730 is configured to slide when the plug 760 of the safety relief valve 700 transitions between a closed position and an open position. A plug housing 734 is defined by a first end of the plug body 730 and is configured to securely receive the plug 760. A spring seat 736 is defined by a second, opposite end of the fixed body 720.
[0080] The bolt 740 includes a shaft 742 and a head 744. The shaft 742 slidably extends through a hole 724 of the fixed body 720, and the threaded end of the shaft 742 is threadedly coupled to the plug body 730. The safety relief valve 700 includes a seal 770 (e.g., an O-ring) configured to form a sealed connection between the shaft 742 of the bolt 740 and the fixed body 720. An end surface of the head 744 of the bolt 740 defines a keyway opening 746 configured to receive a keyway tool 780 for manual operation. An outer radial surface of the head 744 of the bolt defines one or more nested openings 748, each of the nested openings 748 being configured to receive a hooked tool 790 for manual operation. As disclosed in more detail below, the nested openings 748 are covered by the fixed body 720 in a rest position. When the bolt 740 is rotated by the keyway tool 780, the nested openings 748 are aligned with corresponding one or more slots 729 ( Figure 14A and 15B as shown in 15D), which enables the hooked tool 790 to pull at least a portion of the head 744 of the bolt 740 out of the cavity 726 of the fixed body 720.
[0081] The safety relief valve 700 includes a spring 750 extending between and engaging a spring seat 728 of the fixed body 720 and a spring seat 736 of the plug body 730. The spring 750 extends between and engages the fixed body 720 and the plug body 730 to bias the plug 760 in the closed position against a valve seat 775. When the plug 760 is in the closed position, the spring 750 is stretched, and when the plug 760 is in the open position, the spring 750 is compressed.
[0082] Temporarily returning Figure 8 the valve seat 775 is defined by an outlet body 170 of the body 110. When the plug 760 of the safety relief valve 700 is in sealed engagement with the valve seat 775 in the closed position, the pressure relief passage 176 is fluidly disconnected from the exhaust passage 136, such that the outlet section 126 of the chamber 120 is fluidly disconnected from the exhaust section 128.
[0083] When the plug 760 disengages from the valve seat 775 in the open position, the pressure relief passage 176 is fluidly connected to the exhaust passage 136, such that the outlet section 126 is fluidly connected to the exhaust section 128. Subsequently, compressed gas can flow from the outlet section 126 to the exhaust section 128 and out through the exhaust port 650. The safety relief valve 700 is configured to open when the pressure within the outlet section 126 is greater than a predetermined threshold. By opening and directing some of the compressed gas into the exhaust section 128 and discharging it through the exhaust port 650, the safety relief valve 700 can reduce the downstream pressure to less than the predetermined threshold. The safety relief valve 700 is also configured to be manually opened. An operator can choose to manually open the safety relief valve 700 to reduce the downstream pressure.
[0084] Figures 15A to 15D Depicts the sequence for manually opening the safety relief valve 700. The keyway tool 780 and the hook tool 790 are used to manually open the safety relief valve 700.
[0085] Figure 15A Depicts the safety relief valve 700 in a static state. The cover 710 is coupled to the outlet body 170 and covers the other parts of the safety relief valve 700. Figure 15B Depicts the safety relief valve 700 when the cover 710 has been removed from the outlet body 170 to expose the head 744 of the bolt 740 and the slot 729 of the fixed body 720. Figure 15C Depicts the safety relief valve 700 when the keyway tool 780 is inserted into the keyway opening 746 ( Figure 14A ) of the head 744 and the bolt 740 is rotated to align the nested opening 748 ( Figure 14B ) of the head 744 of the bolt 740 with the slot 729 of the fixed body 720. Figure 15D Depicts the safety relief valve 700 after the hook tool 790 has extended through one of the slots 729, been inserted into one of the nested openings 749 of the head 744 of the bolt 740, and pulled the head 744 of the bolt 740 in the axially outward direction. When the bolt 740 is pulled outward, the plug 760 disengages from the valve seat 775 to open the safety relief valve 700. Upon release, the spring 750 ( Figure 14B ) is configured to bias the plug 760 back to the closed position.
[0086] Figure 16Depict a pressure regulator 100 with a seal cover 800 (also referred to as an "inlet seal cover" and an "inlet side seal cover") and a seal cover 900 (also referred to as an "outlet seal cover" and an "outlet side seal cover"). The seal cover 800 is configured to (1) collect any gas that may leak from a connection formed between a pipe 830 and the pressure regulator 100, and (2) redirect the collected gas to an exhaust port 650. The seal cover 900 is configured to (1) collect any gas that may leak from a connection formed between a pipe 930 and the pressure regulator 100, and (2) redirect the collected gas to the exhaust port 650.
[0087] The seal cover 800 includes an inner body 810 and an outer body 820. The inner body 810 is coupled to the inlet body 160 via a thread 812. The seal cover 800 includes a seal 814 (e.g., an O-ring) for forming a sealed connection between the inner body 810 and the inlet body 160. The outer body 820 is coupled to the inlet body 160 via a thread 822. The seal cover 800 includes a seal 824 (e.g., an O-ring) for forming a sealed connection between the outer body 820 and the body 110. The pipe 830 (also referred to as an "inlet side pipe") is configured to extend into the outer body 820 and is firmly received by the inner body 810. The seal cover 800 includes a seal 826 (e.g., an O-ring) for forming a sealed connection between the outer body 820 and the pipe 830.
[0088] The seal cover 900 includes an inner body 910 and an outer body 920. The inner body 910 is coupled to the outlet body 170 via a thread 912. The seal cover 900 includes a seal 914 (e.g., an O-ring) for forming a sealed connection between the inner body 910 and the outlet body 170. The outer body 920 is coupled to the outlet body 170. The seal cover 900 includes a seal 924 (e.g., an O-ring) for forming a sealed connection between the outer body 920 and the outlet body 170. The pipe 930 (also referred to as an "outlet side pipe") is configured to extend into the outer body 920 and is firmly received by the inner body 910. The seal cover 900 includes a seal 926 (e.g., an O-ring) for forming a sealed connection between the outer body 920 and the pipe 930.
[0089] An example two-stage pressure regulator includes a body defining an inlet, an outlet, and a chamber extending between the inlet and the outlet. The chamber includes an inlet section, an intermediate section, and an outlet section. The body includes an upstream valve seat adjacent the inlet. The two-stage pressure regulator includes an upstream piston slidably positioned in the chamber adjacent the inlet to separate the inlet section of the chamber from the intermediate section. The upstream piston includes a first plug configured to engage the upstream valve seat in a first closed position. The first plug is configured to disengage from the upstream valve seat in a first open position to enable compressed gas to flow from the inlet section to the intermediate section. The two-stage pressure regulator includes a seat assembly received in the chamber and secured to the body. The seat assembly includes a downstream valve seat. The two-stage pressure regulator includes a downstream piston slidably positioned in the chamber adjacent the outlet to separate the intermediate section of the chamber from the outlet section. The downstream piston includes a second plug configured to engage the downstream valve seat in a second closed position. The second plug is configured to disengage from the downstream valve seat in a second open position to enable compressed gas to flow from the intermediate section to the outlet section.
[0090] In some examples, the seat assembly further includes a first end and a second end. The first end is received by a first opening of the upstream piston. The second end defines a second opening configured to slidably receive the downstream piston.
[0091] In some examples, the seat assembly further includes a seat spring configured to press the downstream valve seat in place. The seat spring is configured to compress when the second plug engages the downstream valve seat to reduce wear on the downstream valve seat.
[0092] In some examples, the inlet section extends from the inlet to the upstream valve seat, the intermediate section extends from the upstream valve seat to the downstream valve seat, and the outlet section extends from the downstream valve seat to the outlet.
[0093] In some examples, the seat assembly defines one or more holes adjacent the downstream valve seat. When the downstream piston is disengaged from the downstream valve seat in a first open position, the one or more holes fluidly connect the intermediate section to the outlet section.
[0094] In some examples, the body, the upstream piston, and the seat assembly define the intermediate section of the chamber.
[0095] Some examples further include a first spring extending between the upstream piston and the body and engaging the upstream piston and the body to bias the upstream piston to the first open position.
[0096] In some instances, the upstream piston is configured to be in a first open position when a first closing force is less than a first opening force. The first opening force is formed by a combination of a first biasing force of a first spring, an inlet side opening force acting on a first plug in an inlet section of the chamber, and a middle opening force acting on the upstream piston in a middle section of the chamber. In some such instances, the upstream piston is configured to be in a first closed position when the first closing force is greater than or equal to the first opening force. In some such instances, the upstream piston is configured to transition from the first closed position to the first open position when downstream use of compressed gas reduces the pressure in the middle section of the chamber to less than a first predefined pressure threshold. When the pressure in the middle section is less than the first predefined pressure threshold, the first closing force is less than the first opening force. In some instances, the upstream piston further includes a piston body having a first section and a second section. The upstream piston is positioned such that the first closing force is to act on the second section and the middle opening force is to act on the first section. The second section has a larger cross-sectional area than the cross-sectional area of the first section such that the first closing force is greater than the middle opening force.
[0097] In some instances, the upstream piston further includes a first piston body that includes a first section and a second section. A first plug is coupled to the first section of the first piston body. Some such instances further include a first seal. The first piston body further includes a first flange adjacent the first seal and the first section of the first piston body. The first seal is configured to slidably and sealingly engage the body to sealingly separate the inlet section of the chamber from the middle section. Some such instances further include a second seal. The first piston body further includes a second flange located on the second section and adjacent the second seal. The second seal is configured to slidably and sealingly engage the body to sealingly separate the middle section of the chamber from the outlet section. Additionally, some such instances further include a first spring that extends between the second flange and the body and engages the second flange and the body to bias the upstream piston to the first open position.
[0098] Some examples further include a second spring that engages a downstream piston to bias the downstream piston to a second open position. Some such examples further include a threaded shaft member that engages an end of the second spring opposite the downstream piston. The threaded shaft member is configured to adjust a second biasing force of the second spring. In some such examples, the downstream piston is configured to be in the second open position when a second closing force is less than a second opening force. The second opening force is substantially equal to the second biasing force of the second spring. Additionally, in some such examples, the downstream piston is configured to transition from the second closed position to the second open position when downstream use of the compressed gas causes the pressure in the outlet section of the chamber to decrease to less than a second predefined pressure threshold. When the pressure in the outlet section is less than the second predefined pressure threshold, the second closing force is less than the second opening force. In some such examples, the downstream piston is configured to be in the second closed position when the second closing force is greater than or equal to the second opening force.
[0099] In some examples, the downstream piston is configured to be in the second open position when the outlet pressure of the outlet section is less than a second predefined pressure threshold; the upstream piston is configured to be in the first open position when the intermediate pressure in the intermediate section is less than a first predefined pressure threshold; and the downstream piston and the upstream piston are configured to allow compressed gas to flow into the inlet, through the chamber, and out of the outlet when the downstream piston is in the second open position and the upstream piston is in the first open position.
[0100] In some examples, the downstream piston further includes a second piston body that defines a second plug.
[0101] In some examples, the chamber further includes an exhaust section. The body further defines an exhaust port that is fluidly connected to the exhaust section. The exhaust section and the exhaust port are arranged to discharge any compressed gas that leaks from the inlet section, the intermediate section, and the outlet section. Some such examples further include a safety relief valve that is configured to fluidly disconnect the exhaust section from the outlet section in a respective closed position and fluidly connect the exhaust section to the outlet section in a respective open position. The safety relief valve is configured to open when the pressure in the outlet section is greater than a predefined pressure threshold. The safety relief valve is configured to be manually opened. Some such examples further include an inlet side seal cover configured to redirect any compressed gas leaking from the connection to the inlet side pipe to the exhaust port and an outlet side seal cover configured to redirect any compressed gas leaking from the connection to the outlet side pipe to the exhaust port.
[0102] In some examples, the body includes a main body, an inlet body connected to the main body and defining an inlet and an upstream valve seat, and an outlet body coupled to the main body and defining an outlet.
[0103] Some examples further include a sensor coupled to the body and fluidly connected to the outlet section of the chamber.
Claims
1. A two-stage pressure regulator, comprising: A body defining an inlet, an outlet, and a chamber extending between the inlet and the outlet, wherein the chamber includes an inlet section, an intermediate section, and an outlet section, and wherein the body includes an upstream valve seat adjacent the inlet; An upstream piston slidably positioned in the chamber adjacent the inlet to separate the inlet section of the chamber from the intermediate section, wherein the upstream piston includes a first plug configured to engage the upstream valve seat in a first closed position, and wherein the first plug is configured to disengage from the upstream valve seat in a first open position to enable compressed gas to flow from the inlet section to the intermediate section; A seat assembly received in the chamber and fixed to the body, wherein the seat assembly includes a downstream valve seat; and A downstream piston slidably positioned in the chamber adjacent the outlet to separate the intermediate section of the chamber from the outlet section, wherein the downstream piston includes a second plug configured to engage the downstream valve seat in a second closed position, and wherein the second plug is configured to disengage from the downstream valve seat in a second open position to enable the compressed gas to flow from the intermediate section to the outlet section.
2. The two-stage pressure regulator according to claim 1, wherein the seat assembly further includes a first end and a second end, wherein the first end is received by a first opening of the upstream piston, and wherein the second end defines a second opening configured to slidably receive the downstream piston.
3. The two-stage pressure regulator according to claim 1, wherein the seat assembly further includes a seat spring configured to press the downstream valve seat in place, wherein the seat spring is configured to compress when the second plug engages the downstream valve seat to reduce wear on the downstream valve seat.
4. The two-stage pressure regulator according to claim 1, wherein the inlet section extends from the inlet to the upstream valve seat, the intermediate section extends from the upstream valve seat to the downstream valve seat, and the outlet section extends from the downstream valve seat to the outlet.
5. The two-stage pressure regulator according to claim 1, further comprising a first spring extending between the upstream piston and the body and engaging the upstream piston and the body to bias the upstream piston to the first open position.
6. The two-stage pressure regulator according to claim 1, wherein the upstream piston is configured to be in the first open position when a first closing force is less than a first opening force, wherein the first opening force is formed by a first biasing force of a first spring, an inlet-side opening force acting on the first plug in the inlet section of the chamber, and an intermediate opening force acting on the upstream piston in the intermediate section of the chamber.
7. The two-stage pressure regulator according to claim 6, wherein the upstream piston is configured to transition from the first closed position to the first open position when the pressure in the intermediate section of the chamber is reduced to less than a first predefined pressure threshold by downstream use of the compressed gas, and wherein when the pressure in the intermediate section is less than the first predefined pressure threshold, the first closing force is less than the first opening force.
8. The two-stage pressure regulator according to claim 6, wherein the upstream piston further includes a piston body having a first section and a second section, wherein the upstream piston is positioned such that the first closing force is to act on the second section and the intermediate opening force is to act on the first section, and wherein the second section has a larger cross-sectional area than the cross-sectional area of the first section such that the first closing force is greater than the intermediate opening force.
9. The two-stage pressure regulator according to claim 1, further comprising a second spring that engages the downstream piston to bias the downstream piston to the second open position.
10. The two-stage pressure regulator according to claim 9, further comprising a threaded shaft member that engages an end of the second spring opposite the downstream piston, wherein the threaded shaft member is configured to adjust a second biasing force of the second spring.
11. The two-stage pressure regulator according to claim 9, wherein the downstream piston is configured to be in the second open position when a second closing force is less than a second opening force, wherein the second opening force is substantially equal to a second biasing force of the second spring.
12. The two-stage pressure regulator according to claim 11, wherein the downstream piston is configured to transition from the second closed position to the second open position when the pressure in the outlet section of the chamber is reduced to less than a second predefined pressure threshold by downstream use of the compressed gas, and wherein when the pressure in the outlet section is less than the second predefined pressure threshold, the second closing force is less than the second opening force.
13. The two-stage pressure regulator according to claim 1, wherein: the downstream piston is configured to be in the second open position when the outlet pressure in the outlet section is less than a second predefined pressure threshold; the upstream piston is configured to be in the first open position when the intermediate pressure in the intermediate section is less than a first predefined pressure threshold; and the downstream piston and the upstream piston are configured to allow the compressed gas to flow into the inlet, through the chamber, and out of the outlet when the downstream piston is in the second open position and the upstream piston is in the first open position.
14. The two-stage pressure regulator according to claim 1, wherein the chamber further includes an exhaust section, wherein the body further defines an exhaust port fluidly connected to the exhaust section, and wherein the exhaust section and the exhaust port are arranged to exhaust any of the compressed gas that leaks from the inlet section, the intermediate section, and the outlet section.
15. The two-stage pressure regulator according to claim 14, further comprising a safety relief valve configured to fluidly disconnect the exhaust section from the outlet section in a respective closed position and fluidly connect the exhaust section to the outlet section in a respective open position, wherein the safety relief valve is configured to open when the pressure in the outlet section is greater than a predefined pressure threshold, and wherein the safety relief valve is configured to be manually opened.
16. The two-stage pressure regulator according to claim 14, further comprising: an inlet-side seal cover configured to redirect any of the compressed gas leaking from the connection with the inlet-side pipe to the exhaust port; and an outlet-side seal cover configured to redirect any of the compressed gas leaking from the connection with the outlet-side pipe to the exhaust port.