Poppet-style valve arrangement

Abstract

To provide a poppet valve used to control fluid flow and delivery.SOLUTION: A seat carrier subassembly for a valve includes an annular seat carrier body including an annular projection extending radially into a central passage, and an annular plastic seal ring over-molded onto the annular projection, with the annular plastic seal ring defining a seat seal.SELECTED DRAWING: Figure 5A

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the full benefit of U.S. Provisional Patent Application No. 63 / 180,186 (POPPET-STYLE VALVE ARRANGEMENTS), filed April 27, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to fluid flow and delivery devices and methods, and more particularly to poppet valves used to control fluid flow and delivery. [Background technology]

[0003] Poppet valves are well known for use as flow control mechanisms for fluid delivery, flow control, and pressure control of gases and liquids. A poppet valve design includes an axially movable stem having a sealing portion (e.g., an enlarged disk, a tapered end) that seals against an annular valve seat within a valve passage when the stem is in a closed position and axially separates from the seat when the stem is in an open position, allowing fluid to flow through the valve passage. Many different types of fluid control devices utilize poppet valve mechanisms, including diaphragm valves, bellows valves, and pressure regulators. Summary of the Invention

[0004] In accordance with an exemplary embodiment of the present disclosure, a seat carrier subassembly of a valve includes an annular seat carrier body including an annular protrusion extending radially within the central passage, and an annular plastic seal ring overmolded onto the annular protrusion, the annular plastic seal ring defining a seat seal.

[0005] According to another exemplary embodiment of the present disclosure, a valve assembly includes a valve body defining a flow passage between an inlet port and an outlet port, an annular sealing ring surrounding an axial extension of the flow passage 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, wherein the sealing ring interlocks with a radially extending protrusion within the flow passage.

[0006] According to another exemplary embodiment of the present disclosure, a valve seat carrier subassembly includes first and second ring components assembled over an O-ring seal, with a portion of the O-ring seal exposed within an inner diameter gap between inner edges of the first and second ring components to define a valve seat seal.

[0007] According to another exemplary embodiment of the present disclosure, a poppet subassembly includes a poppet having a central portion disposed between axially extending upper and lower stem portions, the central portion defining an upwardly radially extending sealing portion and a downwardly radially extending shoulder portion; a retaining clip secured to the lower stem portion above the enlarged foot portion; and a poppet spring disposed about the lower stem portion and captured between the shoulder and the retaining clip.

[0008] According to another exemplary embodiment of the present disclosure, a pressure regulator includes a valve body, a poppet disposed within the valve body and including an axially extending upper stem portion and a radially extending poppet seal portion, a load mechanism assembled with the valve body and operable to apply a downward load force, and a sensing element disposed between the load mechanism and the poppet to transfer the load force from the load mechanism to the poppet. A lower end of the sensing element includes a socket that receives an enlarged head of the poppet's upper stem portion, the socket being sized to allow axial movement of the poppet relative to the sensing element. The pressure regulator further includes an overtravel spring disposed around the poppet's upper stem portion and compressed between a shoulder of the poppet and an end face of the socket.

[0009] According to another exemplary embodiment of the present disclosure, a pressure regulator includes at least one of: a disc module having a disc housing block that retains a poppet and a seat seal; a load module having a load block secured adjacent to a vent adapter block and retaining a load element configured to apply a load force to a sensing element disposed between the load element and the poppet; a piston module having a piston adapter block secured between the disc housing block and the load block and engaging and retaining the sensing element with the poppet, the sensing element having a piston; and a vent module having a vent adapter block secured between the disc housing block and the load block and defining a vent port in fluid communication with a vent passage in the sensing element. The valve body housing block and at least one of the piston adapter block and the vent adapter block each include a uniformly sized first assembly interface, and the load block and at least one of the piston adapter block and the vent adapter block each include a uniformly sized second assembly interface that mates and sealingly engages 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 vent adapter block, such that the valve body housing block is configured to be assembled directly to the load block by omitting each of the piston module and at least one of the vent module.

[0010] According to another exemplary embodiment of the present disclosure, a pressure regulator includes a valve disc that retains a valve seat, a poppet disposed within the valve disc and axially movable relative to the valve seat, a spring-loaded mechanism assembled with the valve disc and operable to apply a downward load force, and a sensing element disposed between the spring-loaded mechanism and the poppet and transmitting the load force from the spring-loaded mechanism to the poppet. The spring-loaded mechanism includes a spring housing, a spring element retained within the spring housing and disposed between an upper force adjustment plate and a lower spring bearing plate, and an adjustment handle assembled with the spring housing and including a threaded stem portion that threadably engages with the upper force adjustment plate. The upper force adjustment plate is rotatably fixed within the spring housing and axially slidable, so that when a user rotates the adjustment handle, the upper force adjustment plate moves axially and adjusts the downward load force. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic cross-sectional view of a poppet valve assembly. [Figure 2A] FIG. 2 is a schematic cross-sectional view of a pressure reducing regulator valve assembly. [Figure 2B] FIG. 2 is a cross-sectional view of a back pressure regulating valve assembly. [Figure 3] FIG. 2 is a cross-sectional view of a pressure reducing regulator valve subassembly according to an exemplary embodiment of the present disclosure. [Figure 3A] FIG. 4 is a perspective view of a poppet subassembly of the regulator valve subassembly of FIG. 3. [Figure 4] FIG. 2 is a cross-sectional view of a backpressure regulation valve subassembly according to an exemplary embodiment of the present disclosure. [Figure 4A] FIG. 5 is a perspective view of a poppet and sensing mechanism bearing member subassembly of the regulator valve subassembly of FIG. 4. [Figure 5A] FIG. 2 is a cross-sectional view of a valve seat carrier subassembly according to an exemplary embodiment of the present disclosure. [Figure 5B] FIG. 5B is an exploded top perspective view of the valve seat carrier subassembly of FIG. 5A. [Figure 5C] FIG. 5B is a bottom exploded perspective view of the valve seat carrier subassembly of FIG. 5A. [Figure 6A]FIG. 10 is a cross-sectional view of a valve seat carrier subassembly according to another exemplary embodiment of the present disclosure. [Figure 6B] FIG. 6B is an exploded top perspective view of the valve seat carrier subassembly of FIG. 6A. [Figure 6C] FIG. 6B is a bottom exploded perspective view of the valve seat carrier subassembly of FIG. 6A. [Figure 7] FIG. 10 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. [Figure 8] FIG. 10 is a cross-sectional view of a backpressure regulator valve with a diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 9] FIG. 10 is a cross-sectional view of a pressure reducing regulator valve with a sensitive diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 10] FIG. 10 is a cross-sectional view of a backpressure regulating valve with a sensitive diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 11] FIG. 10 is a cross-sectional view of a pressure reducing regulator valve with a piston sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 12] FIG. 10 is a cross-sectional view of a backpressure regulation valve with a piston sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 13] FIG. 10 is a cross-sectional view of a spring-loaded mechanism of a pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 13A] FIG. 14 is an exploded perspective view of the spring-loaded mechanism of FIG. 13. [Figure 14] FIG. 10 is a cross-sectional view of a dome loading mechanism of a diaphragm sensing pressure regulator valve assembly according to another exemplary embodiment of the present disclosure. [Figure 15] FIG. 10 is a cross-sectional view of a dome load mechanism of a piston sensing pressure regulator valve assembly according to another exemplary embodiment of the present disclosure. [Figure 16] FIG. 10 is a cross-sectional view of a self-venting diaphragm sensing mechanism of a pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 17] FIG. 10 is a cross-sectional view of a self-venting piston sensing mechanism of a pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 18] FIG. 1 is a perspective view of a modular piston sensing, venting, spring loaded pressure reducing regulator assembly according to an exemplary embodiment of the present disclosure. [Figure 19] FIG. 19 is a cross-sectional view of the modular regulator assembly of FIG. 18. [Figure 20] FIG. 19 is an exploded perspective view of the regulator assembly of FIG. 18. [Figure 21] 1 is a cross-sectional view of a modular diaphragm sensing, venting, spring loaded pressure reducing regulator assembly according to an exemplary embodiment of the present disclosure; [Figure 22] FIG. 1 is a cross-sectional view of a modular piston sensing, non-vented, spring loaded pressure reducing regulator assembly according to an exemplary embodiment of the present disclosure. [Figure 23] 1 is a cross-sectional view of a modular diaphragm sensing, non-vented, spring loaded pressure reducing regulator assembly according to an exemplary embodiment of the present disclosure. FIG. [Figure 24] FIG. 1 is a perspective view of a modular diaphragm sensing, non-vented, spring loaded backpressure regulator assembly according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] This detailed description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the claimed invention is broader than and is not limited by the exemplary embodiments, and terms used in the claims have their ordinary meanings. For example, while certain embodiments described herein relate to pressure reducing and backpressure regulating valve configurations, features herein may additionally or alternatively be applied to other types of valves, including, for example, user-operable regulator valves, shut-off valves, check valves, and relief valves. As used herein, the terms "poppet valve" and "poppet-type valve" are intended to broadly include any valve including a stem carrying a flow restricting member, which may, but need not, move relative to an annular valve seat by longitudinal movement of the stem and into sealing engagement with the seat. The terms "sealing" and "sealingly engaging" are intended to include a condition of reduced flow resulting from contact between a sealing surface and a seating surface, in addition to a leak-tight or fluid-tight seal.

[0013] While various inventive aspects, concepts, and features of the present invention may be described and illustrated herein as embodied in combination in exemplary embodiments, these various aspects, concepts, and features may be used individually or in various combinations and subcombinations thereof in many alternative embodiments. Unless expressly excluded herein, all such combinations and subcombinations are intended to be within the scope of the present invention. Furthermore, although various alternative embodiments of various aspects, concepts, and features of the present invention may be described herein, including alternative materials, structures, configurations, methods, circuits, devices, and components, software, hardware, control logic, and alternatives in terms of form, fit, and function, such descriptions are not intended to be a complete or exhaustive list of all available alternative embodiments, whether currently known or later developed. Those skilled in the art will readily be able to adopt one or more of the aspects, concepts, or features of the present invention into additional embodiments and uses within the scope of the present invention, even if such embodiments are not expressly disclosed herein. Furthermore, while some features, concepts, or aspects of the present invention may be described herein as preferred mechanisms or methods, such description is not intended to imply that such features are required or necessary unless expressly so stated. Furthermore, to aid in understanding the present disclosure, example or representative values ​​and ranges may be included; however, such values ​​and ranges should not be construed in a limiting sense and are intended to be critical values ​​or ranges only if expressly stated as such. Parameters identified as "approximately" or "about" a particular value are intended to include both the particular value and values ​​within 10% of the particular value, unless otherwise specified. Furthermore, it should be understood that the drawings accompanying this application may, but need not, be to scale and may be understood as teaching various ratios and proportions apparent in the drawings.Furthermore, while various aspects, features, and concepts may be expressly identified herein as being inventive or forming part of the invention, such identification is not intended to be exclusive; rather, there may be aspects, concepts, and features of the invention that are fully described herein without being expressly identified as such or as part of a particular invention; instead, the invention is set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to the inclusion of every step as required in all cases, nor should the order in which steps are presented be construed as necessary or essential unless explicitly stated.

[0014] 1 , in the illustrative embodiment shown schematically, a poppet-type valve assembly 10 includes a valve disc 20 defining a valve passage 22 between an inlet port 21 and an outlet port 23, and an annular valve seat 30 extending around an axially extending central portion 24 of the valve passage. A poppet 40 is assembled with the valve disc 20 and includes an axially extending poppet stem 41 and a radially extending poppet seal 42. An actuator or loading mechanism 50, when assembled with the poppet stem 41, controls axial movement of the poppet 40 between a closed position in which the poppet seal 42 seals against the valve seat 30 (e.g., to prevent flow above an allowable leakage rate) and an open position in which the poppet seal axially separates from the valve seat, allowing fluid to flow through the axially extending portion 24 of the valve passage 22. The actuator 50 may be user-operable (e.g., manually, pneumatically, or electrically operable) for selective movement of the poppet 40. Alternatively, the actuator 50 may be configured to automatically move or enable movement of the poppet under certain predetermined system conditions. For example, the actuator arrangement may be configured to cause or enable automatic movement of the poppet 40 at a system fluid pressure threshold, such as to relieve excess fluid pressure from the system (in the case of a relief valve), prevent backflow (in the case of a check valve), or reduce outlet pressure (in the case of a pressure regulator). Examples of pressure regulators having poppet-type valve arrangements are disclosed in a product catalog entitled PRESSURE REGULATORS RHPS SERIES, which is publicly available online and otherwise from Swagelok Company and is incorporated herein by reference in its entirety.

[0015] FIG. 2A schematically illustrates a pressure reducing regulator 10a having an adjustment mechanism including a sensing element 80a (e.g., a piston or diaphragm) that responds to a load force F applied by a loading mechanism 50a (e.g., a compressed spring or fluid pressurized chamber) due to the downward biasing movement of a poppet 40a. SWhen the lower side of the sensing element 80a is subjected to the system fluid force F, the system fluid force F is converted into the biasing element load force F S When the load force F exceeds the load force F, the poppet 40a moves upward (e.g., by direct attachment or separately driven movement of the poppet). S biases the poppet 40a toward an open position away from sealing engagement with the valve seat 32a. S When the downstream flow pressure exceeds the desired pressure, corresponding to a system fluid force F exceeding 0.05 W, the upward movement of the sensing element 80a reduces the outlet pressure by moving the poppet upward against the valve seat 32a toward the closed position. When the downstream flow pressure reduces below the desired pressure, the biasing element load force F S overcomes the system fluid force F, causing the sensing element 80a to move downward, which in turn causes the poppet 40a to move downward toward the open position.

[0016] FIG. 2B schematically illustrates a backpressure regulator 10b, similar to the pressure reducing regulator 10a of FIG. 2A, having an adjustment mechanism including a sensing element 80b (e.g., a piston or diaphragm) that responds to a load force F applied by a loading mechanism 50b (e.g., a compressed spring or fluid pressurized chamber) due to the downward biasing movement of the poppet 40b. S The lower side of the sensing element 80b is subjected to the system fluid force F, and the system fluid force F is converted into the load mechanism load force F. S When the load force F exceeds the load force F, the poppet 40b moves upward. S The load mechanism load force F biases the poppet 40b toward the closed position in sealing engagement with the valve seat 32b. S When the upstream flow pressure exceeds the desired pressure, corresponding to a system fluid force F exceeding 100 W, the upward movement of the sensing element 80b reduces the inlet or upstream pressure by moving the poppet upward against the valve seat 32b toward the open position. When the upstream flow pressure reduces below the desired pressure, the loading mechanism load force F S overcomes the system fluid force F, causing the sensing element 80b to move downward, which in turn causes the poppet 40b to move downward toward the closed position.

[0017] Many different regulator disc, poppet, and seat configurations may be utilized in various combinations. Figure 3 illustrates an exemplary pressure-reducing regulator valve subassembly 101, including a regulator disc 110 defining a valve passage 112 between an inlet port 111 and an outlet port 113, and an annular seat sealing surface 132 disposed within a central cavity 114 extending axially through the disc between the inlet and outlet ports. A poppet 140 is assembled with the disc 110 and includes an axially extending upper poppet stem 141 for engaging (directly or indirectly) a sensing element and a radially extending poppet seal 142, the poppet being axially movable between a lower, open position in which the poppet seal is axially spaced from the seat sealing surface 132 and an upper, closed position in which the poppet seal is in sealing engagement with the seat sealing surface. The outlet port 113 is in fluid communication with a sensing interface chamber 119 defined at least in part by the upper end of the disc 110. In such a configuration, a downward force applied to the poppet 140 through a sensing mechanism (described in detail below) that exceeds the upward force applied by the outlet flow pressure will move the poppet toward the lower, open position.

[0018] 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 the valve seat sealing surface 132 is disposed on a valve seat carrier 130 retained within the central cavity of the housing.

[0019] As shown in FIG. 3 , the main housing 115 can be provided with a support ring 105 sized to support the regulator in an upright position (e.g., on a work bench) prior to installation. The support ring 105 can be provided from a flexible plastic (e.g., nylon) to facilitate snap-on (and snap-off) engagement with a lower lip 115-1 on the main housing 115. During installation, the support ring 105 can be removed or retained with the regulator, for example, as a visual indicator (e.g., color code, text, or symbols). In other embodiments, the support ring can provide for mounting additional hardware or devices. For example, as shown in FIG. 7 , the heater block 102 (or other fixture block) can be secured to the support ring 105 using threaded fasteners 106 installed through mounting apertures 107 in the support ring and threaded into mounting holes 103 in the heater block 102.

[0020] The exemplary body plug 120 includes a central cavity 121 that receives the lower stem portion 143 of the poppet 140, a top surface 122 that engages the seat carrier 130 to secure it against the first counterbore 116 of the central cavity 114, and one or more apertures 123 positioned to align with the disc inlet port 111 when the poppet 140 is in the open position to allow fluid to flow from the inlet port into the body plug cavity 121 and between the poppet sealing portion 142 and the seat sealing surface 132 to the outlet port 113. The apertures 123 can 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 disc housing 115. The seat carrier 130 may be provided with an outer annular groove 133 that retains a gasket 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, for example, to limit axial compression of the seat carrier 130.

[0021] As shown, the poppet 140 can have an internal passage 145 extending from the poppet's lower stem portion 143 to the top of the poppet downstream of the seat sealing surface 132, and a gasket seal 147 provides a seal between the enlarged lower foot 148 of the poppet's lower stem portion and the narrower base 125 of the body plug cavity 121 so that when the poppet 140 is in the closed position, inlet or upstream fluid pressure on the poppet is counteracted by outlet or downstream fluid pressure. This configuration may be referred to as a balanced poppet design, which may result, for example, in reduced seat load and, for example, reduced wear / deformation of the seat sealing surface 132. In such a configuration, a poppet spring 146 can be provided within the body plug cavity 121 and compressed between the body plug 120 and the poppet 140 (e.g., at a shoulder 144) to provide a consistent closing / sealing force on the poppet independent of system fluid pressure.

[0022] To facilitate assembly of the pressure reducing regulator valve subassembly 101, the poppet spring 146 may be pre-assembled with the poppet 140 as a poppet subassembly, e.g., in an uncompressed or partially compressed state, allowing the body plug threads to initially engage with the housing threads without the need to compress the spring. Once the body plug 120 is partially threaded into the central cavity 114, the body plug is fully threaded into the central cavity, achieving the desired compression of the poppet spring 146, and the body plug end face 122 engages the second counterbore 117, providing a hard stop for the threading. While many different configurations can be used to provide the pre-assembled spring on the poppet, in the illustrated embodiment, an E-clip or other such retaining clip 109 is secured above the enlarged foot 148 of the lower poppet stem 143 to provide a lower bearing surface for the poppet spring 146, as more clearly shown in FIG. 3A . The spring 146 may, but need not, be preloaded or spring loaded between the poppet 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.

[0023] In an exemplary method, to assemble the seat carrier 130, poppet 140, and body plug 120 with the disc housing 115, the seat carrier 130 is installed into the housing through the lower end of the central cavity 114. The poppet 140 with a pre-assembled poppet spring 146 is installed into the central cavity 114, with the upper poppet stem 141 extending through a central bore in the seat carrier 130. The body plug is installed over the lower poppet stem 143 and threaded into the disc housing 115, securing the seat carrier 130 against the first counterbore 116, and the body plug counterbore 124 engages the retaining clip 109, moving it away from the foot 148 of the lower poppet stem 143 and compressing the poppet spring 146 to the desired compression.

[0024] 4 illustrates an exemplary backpressure regulator valve subassembly 201 including a regulator valve disc 210 defining a valve passage 212 between an inlet port 213 and an outlet port 211, and an annular seat sealing surface 232 disposed within an axially extending central cavity 214 of the valve disc between the inlet and outlet ports. A poppet 240 is assembled with the valve disc 210 and includes an axially extending upper poppet stem 241 for engaging (directly or indirectly) a sensing mechanism and a radially extending poppet seal portion 242, the poppet being axially movable between a lower, closed position in which the poppet seal portion sealingly engages the seat sealing surface 232 and an upper, open position in which the poppet 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 the upper end of the valve disc housing 215. In such a configuration, a downward force applied to the poppet 240 through a sensing mechanism (described in more detail below) that exceeds the upward force applied by the inlet flow pressure will move the poppet toward the lower, closed position.

[0025] The valve disc may be provided as a single piece or monolithic component including an integrally formed valve seat, although in other embodiments the valve disc may include a multi-component assembly to facilitate installation and / or replacement of, for example, a poppet, valve seat, or other such components. In the illustrated example, the valve disc 210 includes a valve housing 215 and a body plug 220 assembled (e.g., threadedly engaged) with a central cavity 214 of the housing, with a seat sealing surface 232 disposed on a seat carrier 230 retained within the central cavity of the housing.

[0026] The exemplary body plug 220 includes a central cavity 221 that receives a lower stem portion 243 of a poppet 240, a top surface 222 that engages the seat carrier 230 to secure the seat carrier against the first counterbore 216 of the central cavity 214, and one or more apertures 223 positioned to align with the disc outlet port 211 when the poppet 240 is in the open position to allow fluid to flow from the inlet port 213, through the poppet sealing portion 242 and the seat sealing surface 232, into the body plug cavity 221, and through the aperture(s) 223 to the outlet port 211. The apertures 223 can be circumferentially spaced about 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 disc housing 215. The seat carrier 230 may be provided with an annular end face groove 235 that retains a gasket / 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, for example, to limit axial compression of the seat carrier 230.

[0027] As shown, the poppet 240 may be provided with an internal passage 245 extending from the poppet's lower stem portion 243 to the top of the poppet upstream of the seat sealing surface 232, with a gasket seal 247 providing a seal between the enlarged lower foot 248 of the poppet's lower stem portion and the narrower base 225 of the body plug cavity 221 so that when the poppet 240 is in the closed position, inlet or upstream fluid pressure on the poppet is counteracted by outlet or downstream fluid pressure. This configuration may be referred to as a balanced poppet design, which may, for example, reduce seat load, resulting in, for example, reduced seat wear / deformation.

[0028] In the backpressure regulating valve subassembly, the seat may be further protected from excessive poppet closing force exerted by the sensing mechanism by an over-travel spring disposed between the sensing mechanism and the poppet seal, allowing the sensing mechanism to advance further axially downward when engaging the poppet seal with the valve seat seal. According to an exemplary aspect of the present disclosure, the poppet may be interlocked with the sensing mechanism bearing member using a joint, which may be configured to allow limited axial movement of the poppet relative to the sensing mechanism bearing member with the over-travel spring captured between opposing surfaces of the poppet and the sensing mechanism bearing member. This joint configuration may facilitate assembly of the poppet with the sensing mechanism.

[0029] While many different joint configurations may be utilized, in an exemplary embodiment, one of the poppet and bearing member is provided with an enlarged or flanged head, and the other of the poppet and bearing member includes a grooved socket portion that retains the head with an over-travel spring compressed between portions of the poppet and bearing member such that the over-travel spring biases a sealing portion of the poppet away from the bearing member. When the loading force of the sensing mechanism moves the poppet to a closed position, excess closing force from the sensing mechanism compresses the over-travel spring between the poppet and bearing member, thereby limiting the closing force the poppet applies to the seat seal.

[0030] 4A , an enlarged or flanged head 249 of the poppet 240 is received in a grooved socket portion 289 of the sensing mechanism bearing member 282, and an over-travel spring 246 is compressed between a lower end surface 287 of the bearing member and an upper shoulder 244 of the poppet 240, thereby biasing the poppet's sealing portion 242 away from the bearing member. When the sensing mechanism load force moves the poppet 240 to the closed position, excess closing force from the sensing mechanism compresses the over-travel spring 246 between the poppet and the bearing member 282, thereby limiting the closing force the poppet applies to the valve seat sealing surface 232.

[0031] In an exemplary method, the seat carrier 230, poppet 240, and body plug 220 are assembled with the disc housing 215 of the backpressure regulator valve arrangement 201 by sliding the overtravel spring 246 over the upper poppet stem 241 and seating the poppet's head 249 in the grooved socket 289 of the sensing mechanism bearing member 282, thereby compressing the overtravel spring 246 between the poppet and the bearing member. The poppet 240 is seated in the housing 215 through the upper end of the central cavity 214, and the seat carrier 230 is seated in the housing through the lower end of the central cavity 214. The body plug 220 is placed over the lower poppet stem 243 and threaded into the disc housing 215, securing the seat carrier 230 against the first counterbore 216.

[0032] Many different types of valve seat carrier assemblies are available, for example, to accommodate different system pressures, temperatures, and fluid / chemical properties. In the exemplary embodiment of Figures 3 and 4, the valve seat carrier 130, 230 includes an annular, single-piece valve seat 131, 231 having a contoured inner diameter that defines a seat sealing surface 132, 232. The valve seat carrier 130, 230 may be provided in any suitable material, including, for example, plastics such as polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), and polyetheretherketone (PEEK). In the pressure-reducing regulator subassembly 101, the valve seat carrier includes an outer annular groove 133 that retains a gasket seal 134 for sealing engagement with the first counterbore 116. In the backpressure regulator subassembly 201, the valve seat carrier 230 includes an annular end face groove 235 that retains a gasket seal 236 for sealing engagement with the first counterbore 216.

[0033] In some applications, for example, in high-pressure and / or high-temperature applications, the use of harder materials (e.g., materials having a hardness of at least 90 Shore D), such as metal (e.g., stainless steel) seats and seals, can be highly susceptible to seat leakage due to, for example, seat seal misalignment, surface mismatch, contamination, or wear. Especially at high pressures, small amounts of leakage can cause erosion of the sealing surfaces, resulting in much larger leaks past the seat. Furthermore, in some valve assemblies, the closing force applied to the poppet stem may be minimal and therefore insufficient to compensate for misalignment of the sealing surfaces, causing the seat and seals to deflect or deform.

[0034] According to one aspect of the present disclosure, the valve seat may be provided as an annular, softer material (e.g., having a hardness of less than about 100 HRM) sealing ring that is overmolded, overlaid, or otherwise interlocked with or secured to a harder (e.g., greater than about 80 HRB) inner circumferential rib, flange, rail, or other such protrusion that protrudes into the center of the valve passage. The rigid underlying protrusion allows for the use of a relatively thin (e.g., between about 0.05 inches and about 0.10 inches) sealing ring that minimizes thermal expansion, material flow, and deformation of the softer sealing ring material while providing rigid support to facilitate use in high-pressure (e.g., up to about 6000 psi) applications.

[0035] 5A, 5B, and 5C illustrate an exemplary annular seat carrier subassembly 330, similar to the seat carriers 130, 230 of FIGS. 3 and 4, including a seat carrier body 331 having an inner circumferential annular protrusion 338 and an annular sealing ring 337 overmolded, overlaid, 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 seal (e.g., as shown in FIGS. 3 and 4). While various protrusions can be utilized, in the illustrated embodiment, the protrusion 338 is formed as an annular, circumferentially continuous, generally T-shaped rail that includes a narrower neck portion and an enlarged head portion shaped to be retained in interlocking engagement with a complementary shaped channel portion 339 of the sealing ring 337. In other embodiments, the protrusions may have different cross-sectional shapes and / or may be circumferentially discontinuous, for example, may vary in cross-sectional shape around the circumference, or may be formed from two or more circumferentially spaced segments.

[0036] Similar to the seal rings 130, 230 of FIGS. 3 and 4, the seat carrier 330 may include a first annular groove 333 (e.g., an outer annular groove) that retains a gasket seal 334 for sealing engagement with a counterbore in the valve body (e.g., counterbore 116 in the pressure reducing valve subassembly 101 of FIG. 4) to provide a downward-facing seat seal face 332, and / or a second annular groove 335 (e.g., annular end face groove 335) that retains a gasket seal 336 for sealing engagement with a counterbore in the valve body (e.g., counterbore 216 in the backpressure regulator valve subassembly 201 of FIG. 4) to provide an upward-facing seat seal.

[0037] While the seal ring may be press-fit or otherwise assembled onto the protrusion, in other embodiments, the seal ring 337 may be injection molded or overmolded onto the annular protrusion 336, which can provide consistency in the seal ring's roundness, surface finish, and material thickness. Various injection molding methods can be used. In an exemplary configuration, injection molding using a diaphragm gate located at a non-critical location g on the seal ring's inner diameter, spaced from the contoured sealing surface 332, can prevent injection molding streamlines and the resulting uneven shrinkage and inconsistent roundness of any seal ring.

[0038] In yet other embodiments, additive manufacturing (e.g., 3D printing) can be used to form the seal ring over the underlying protrusion. Examples of additive manufacturing techniques that can be used include, for example, laser powder bed fusion (direct metal laser sintering or "DMLS", selective laser sintering / melting or "SLS / SLM", or layered 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-steered net shaping or "LENS", electron beam wire deposition).

[0039] Any suitable material can be used to provide adequate sealing within the valve. For example, the sealing ring can be made of a suitable plastic (e.g., PEEK) and the sealing ring retaining projection can be made of 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).

[0040] In other embodiments (not shown), the seal ring retention protrusion is integrally formed with the valve disc (eg, as a protrusion into the valve disc channel), thereby eliminating a separate valve seat carrier component.

[0041] According to another aspect of the present disclosure, the seat seal may be defined by an elastomeric gasket or O-ring, for example, to provide an effective seal in lower-pressure applications (e.g., less than about 1000 psi). While the O-ring / gasket seat seal may be carried by the poppet, in other embodiments, the seat carrier arrangement may be configured to fixedly hold the O-ring gasket seal and provide the seat seal on the poppet (e.g., a one-piece poppet). In an exemplary embodiment, the seat carrier may include a separate first ring component and a separate ring component assembled (e.g., loosely assembled) over the O-ring seal, with a portion of the O-ring seal exposed in the inner diameter gap between the inner edges of the first and second ring components. Limiting the exposure of the O-ring seal may minimize extrusion, contact, or other damage to the O-ring during valve operation.

[0042] 6A, 6B, and 6C show an exemplary annular seat carrier subassembly 430, similar to the seat carriers 130, 230, 330 of FIGS. 4, 5, and 6A-6B, including first and second ring components 431-1, 431-2 assembled over an O-ring seal 437, with a portion of the O-ring seal exposed in an inside diameter gap between inner edges of the first and second ring components to define a seat seal portion 432. The first and second ring components 431-1, 431-2 may be sized and configured such that when the seat carrier 430 is installed within a regulator valve subassembly (e.g., with the seat carrier secured between a body plug and a counterbore in the valve housing), the first and second ring components compress the O-ring seal 437, squeezing the seat seal portion 432 of the O-ring seal through the inside diameter gap 468 between the first and second ring components.

[0043] In the illustrated embodiment, the first outer ring component 431-1 includes a radially inwardly extending flange 461 defining an internal counterbore 462 and an axially upwardly (in the orientation of FIG. 6A ) extending flange 463 defining an external counterbore 464. The second inner ring component 431-2 includes an outer periphery 465 that seats within the external counterbore 464 of the outer ring component 431-1 and an axially downwardly extending flange 466 that extends toward the radially inwardly extending flange 461 of the outer ring component to define an annular cavity 467 for an O-ring seal and inner diameter gap 468.

[0044] Similar to the seal rings 130, 230, 330 of FIGS. 3, 4, and 5A-5C, the seat carrier 430 may include a first annular groove 433 (e.g., an outer annular groove) that retains a gasket seal 434 for sealing engagement with a counterbore in the valve body (e.g., counterbore 116 in the pressure reducing valve subassembly 101 of FIG. 3) to provide a downward-facing seat seal 432, and / or a second annular groove 335 (e.g., an annular end face groove) that retains a gasket seal 436 for sealing engagement with a counterbore in the valve body (e.g., counterbore 216 in the backpressure regulator valve subassembly 201 of FIG. 4) to provide an upward-facing seat seal.

[0045] Any suitable material can be used to provide adequate sealing performance within the valve. For example, the valve seat carrier component(s) can be provided from a metal (e.g., stainless steel) material, and the gasket / O-ring seal can be formed from a suitable elastomer (e.g., EPDM, perfluoroelastomer, or nitrile).

[0046] In other embodiments (not shown), one of the first and second ring components can be integrally formed with the valve body, thereby eliminating one of the separate valve seat carrier components.

[0047] According to another aspect of the present disclosure, one or more regulator valve subassembly components may be configured to facilitate modular interchangeability of components in multiple regulator assemblies, including, for example, different flow regulation configurations (e.g., pressure reduction, backpressure regulation), different types of valve seat seals (e.g., hard plastic, soft elastomer), different loading mechanisms (e.g., spring loaded and / or dome loaded mechanisms), different regulator sensing mechanisms (e.g., diaphragm sensing mechanisms, piston sensing mechanisms), and other optional features (e.g., self-venting configurations).

[0048] For example, as shown in Figures 3 and 4, the disc (e.g., disc housing 115 / 215 and disc plug 120 / 220) can be configured for use with both pressure-reducing and back-pressure regulators. As shown, a first port 111 / 211 of the disc housing 115 / 215 serves as the inlet port for the pressure-reducing regulator (Figure 3) and the outlet port for the back-pressure regulator (Figure 4), and a second port 113 / 213 of the disc housing serves as the outlet port for the pressure-reducing regulator and the inlet port for the back-pressure regulator. To accommodate the enlarged head-and-socket joint of the back-pressure regulator arrangement (described in more detail above), the central cavity 114 / 214 of the disc housing 115 / 215 can be provided with an enlarged upper recess 118 / 218 sized to receive a grooved socket portion 289 and a lower end surface 287 of the bearing member 282. A guide ring 170 may be positioned within the enlarged upper recess 118 / 218 to closely receive the upper poppet stem 141 of the pressure reducing regulator valve arrangement to guide the upper poppet stem. While many different guide rings may be utilized, in the illustrated embodiment, the guide ring 170 includes first and second annular guide ring elements 171, 172 that capture an O-ring 173 that provides a guide seal for the upper poppet stem 141. The enlarged upper recess 118 / 218 and first guide ring element 171 may include mating threads to threadably retain the guide ring 170 within the disc housing 115. As shown, the disc housing 115 / 215 may include a bypass channel 113-1 / 213-1 extending from the second port 113 / 213 to the sensing interface chamber 119 / 219 to pressurize a sensing mechanism within the pressure reducing regulator valve arrangement.

[0049] By using the same plug housing 115 / 215 and plug 120 / 220 for both the pressure reducing regulator configuration and the back pressure regulator configuration, a uniform recess is provided between the first counterbore 116 / 216 and the second counterbore 117 / 217 for retaining the seat carrier in both configurations. As shown in Figures 3, 4, 5A-5C, and 6A-6C, the seat carrier 130 / 230, 330, 430 may be provided with a first annular groove (e.g., outer annular groove 133 / 233, 333, 433) and a second annular groove (e.g., end face annular groove 135 / 235, 335, 435) and may be used for both the pressure reducing regulator configuration and the back pressure regulator configuration. When the seat carrier 130 / 230, 330, 430 is installed with the seat sealing surface 132, 332, 432 facing downward and engaging the poppet seal portion 142 of the pressure reducing regulator poppet 140 (FIG. 3), the gasket / O-ring seal 134, 334, 434 is retained in the first annular groove 133 / 233, 333, 433 for sealing engagement with the first counterbore 116. When the seat carrier 130 / 230, 330, 430 is installed with the seat sealing surface 132, 332, 432 facing upward and engaging the poppet seal portion 242 of the backpressure regulator poppet 240, the gasket / O-ring seal 136, 336, 436 is retained in the second annular groove 135 / 235, 335, 435 for sealing engagement with the first counterbore 216 (FIG. 4). In the backpressure regulator valve subassembly 201 , the valve seat carrier 230 includes an annular end face groove 235 that retains a gasket seal 236 for sealing engagement with the first counterbore 216 .

[0050] For example, in lower outlet pressure applications (e.g., spring-loaded assemblies used with outlet pressures up to about 600 psi), and in applications where greater accuracy in sensing changes in outlet pressure is desired, the diaphragm sensing mechanism used can be adapted for use with modular pressure reducing and back pressure regulator configurations, as described herein.

[0051] 7, the diaphragm sensing mechanism 580 shown with the pressure reducing regulator valve subassembly 101 of FIG. 3 includes a flat, flexible disk of material (e.g., an elastomer, plastic, or metal suitable for the system fluid) forming a diaphragm 581 having an outer periphery clamped or fixed between body surfaces (e.g., between opposing faces of the disc housing block 115 and a spring or dome load housing block fastened by a threaded arrangement). As shown, the diaphragm sensing mechanism 580 may include a diaphragm screw or bearing member 582 that, when installed through a central opening in the diaphragm 581, can provide a more robust engagement between the diaphragm, poppet 140, and a load mechanism (described below), for example, to protect the diaphragm from damage. In the illustrated example, upper and lower plates 583, 584 are secured to diaphragm screws 582 on either side of diaphragm 581 by nuts 585 threaded onto the diaphragm screws to provide further support to the diaphragm.

[0052] In the embodiment shown in FIG. 8, the diaphragm sensing mechanism 680 shown with the backpressure regulating valve subassembly 201 of FIG. 4 can use the same diaphragm 581 / 681, upper and lower plates 583 / 683, 584 / 684, and nuts 585 / 685 as the diaphragm sensing mechanism 580 of FIG. 7, except that the diaphragm sensing mechanism 680 includes a diaphragm screw or bearing member 682 having a lower portion defining a poppet head retaining socket 689 and an overtravel spring engaging end face 687, similar to that shown in FIG. 4 and described above.

[0053] For example, in applications where even greater accuracy / sensitivity in sensing changes in outlet pressure is desired, diaphragm sensing mechanisms having larger diaphragms used can be adapted for use with modular pressure reducing and back pressure regulator valve configurations as described herein.

[0054] 9, the sensitive diaphragm sensing mechanism 780 shown with the pressure reducing regulator valve subassembly 101 of FIG. 3 includes an enlarged diaphragm 781 having an outer periphery that is clamped or secured between an upper diaphragm shell member 781-1 and a lower diaphragm shell member 781-2, which may be secured together by a threaded arrangement or bolted to the disc housing block 115 (through mounting holes in the lower diaphragm shell member). As shown, the diaphragm sensing mechanism 780 may include a diaphragm screw or bearing member 782 that, when installed through a central opening in the diaphragm 781, may provide a more robust engagement between the diaphragm, poppet 140, and a loading mechanism (described below), for example, to protect the diaphragm from damage. In the illustrated example, upper and lower plates 783, 784 are secured to diaphragm screws 782 on either side of diaphragm 781 by nuts 785 threaded onto the diaphragm screws to provide further support to the diaphragm.

[0055] In the embodiment shown in FIG. 10, the highly sensitive diaphragm sensing mechanism 880 shown with the backpressure regulating valve subassembly 201 of FIG. 4 can use the same diaphragm 781 / 881, upper and lower plates 783 / 883, 784 / 884, and nuts 785 / 885 as the diaphragm sensing mechanism 780 of FIG. 9, except that it includes a diaphragm screw or bearing member 882 having a lower portion defining a poppet head retaining socket 889 and an overtravel spring engaging end face 887, similar to that shown in FIG. 4 and described above.

[0056] For example, in higher pressure spring loaded applications (e.g., about 600 psi) and where greater resistance to damage caused by pressure spikes is desired, the piston sensing mechanism used can be adapted for use with modular pressure reducing and back pressure regulator configurations, as described herein.

[0057] In the embodiment shown in FIG. 11 , the piston sensing mechanism 980 shown with the pressure reducing regulator valve subassembly 101 of FIG. 3 includes an axially elongated piston member 982 received within a central piston bore 984 of a piston adapter plate or block 983 secured between body surfaces (e.g., between opposing faces of the disc housing block 115 and a spring or dome load housing block fastened by a threaded arrangement). While many different types of sensing piston members can be used, in the illustrated embodiment, the piston member 982 includes a stepped configuration that allows the fluid driving load applied to the piston to be adjusted by selecting the stepped diameter at which O-ring seals 988-1, 988-2, 988-3 are located, thereby varying the top piston surface upon which fluid pressure acts. The central piston bore 984 of the piston adapter block 983 is sized and shaped to accommodate this stepped piston configuration. Additionally, the lower end of the piston adapter block 983 can be shaped to fit over the upper end of the valve housing 115 / 215 so that the same valve housing can be used with both the diaphragm sensing mechanism 580 and the piston sensing mechanism 980. Additionally, a gasket seal 981 can be provided between the valve body housing block 115 and the piston adapter block 983.

[0058] In the embodiment shown in FIG. 12, the piston sensing mechanism 1080 shown with the backpressure regulating valve subassembly 201 of FIG. 4 can use the same piston adapter block 983 / 1083 as the piston sensing mechanism 980 of FIG. 12, except that the piston sensing mechanism 1080 includes a piston member 1082 having a lower portion defining a poppet head retaining socket 1089 and an overtravel spring engaging end face 1087, similar to that shown in FIG. 4 and described above.

[0059] For example, the spring loaded mechanism used can be adapted for use with modular pressure reducing and back pressure regulator valve configurations, including both diaphragm and piston sensing mechanisms, as described herein, to allow for manual adjustment of the regulator pressure setting.

[0060] In the embodiment shown in FIG. 13, the spring loading mechanism 1150 includes a resilient, compressible spring element (e.g., one or more coil springs) 1152 retained within a spring housing 1151 assembled with the valve body (e.g., by a mounting screw installed through an apertured mounting base 1151-1 of the spring housing) and, when compressed between an upper force adjustment plate 1153 and a lower spring bearing plate 1154, applies a loading force to a sensing mechanism bearing member 1182 (e.g., a piston or diaphragm screw). As shown, the diaphragm screws 582, 682 and piston members 982, 1082 of the modular assemblies described above may include uniform load-engaging upper ends 586, 686, 786, 886, 986, 1086, 1186 to accommodate use of the same spring-loaded mechanism 1150 with any of the modular pressure reducing and back pressure regulating valve configurations described herein (those having both diaphragm and piston sensing mechanisms).

[0061] The force adjustment plate 1153 can be adjusted (e.g., raised or lowered) to adjust the amount of spring force applied to the sensing mechanism bearing member 1182 via the spring bearing plate 1154. While 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 stem 1156, such that the handle and threaded stem are rotatable to drive the fixed force adjustment plate 1153 up or down to adjust the compression of the spring 1152. The force adjustment plate 1153 is secured in rotation by a set screw 1157 (or other suitable protrusion) on the plate that rides into a vertical slot 1158 in the spring housing 1151, the slot being sized to provide the desired upper and lower limits for the force adjustment plate. A cover panel 1159 may be provided within the slot 1158, for example, to seal out debris, moisture, or other contaminants.

[0062] For example, the diaphragm sensing dome load configuration used can be adapted for use with modular diaphragm sensing pressure reducing regulator and back pressure regulator configurations so that the regulator pressure setting is remotely adjustable.

[0063] In the embodiment shown in FIG. 14, dome loading mechanism 1250 includes a dome housing 1251 assembled with a valve body (e.g., by mounting screws) to define a dome chamber 1252, and includes a pressure port 1253 that supplies pressurized fluid to the dome chamber at a set pressure (e.g., from a secondary pressure regulator) to apply a corresponding load force against a diaphragm 1281 of a diaphragm sensing mechanism 1280 (e.g., pressure reducing regulator diaphragm sensing mechanism 580 of FIG. 8 or back pressure regulator diaphragm sensing mechanism 680 of FIG. 9).

[0064] For example, the piston sensing dome load configuration used can be adapted for use with modular piston sensing pressure reducing regulator and back pressure regulator configurations so that the regulator pressure setting is remotely adjustable.

[0065] 15, dome load mechanism 1350 includes upper and lower dome housing shell members 1351-1, 1351-2 assembled with a valve body (e.g., by mounting screws) to define a dome chamber 1352, a dome load diaphragm 1359 having an outer periphery captured between the upper and lower shell members, and a diaphragm screw 1354 threaded through a central opening in the dome load diaphragm and positioned to engage an upper end 1386 of a sensing element bearing member 1382 (e.g., piston members 982, 1082 in FIGS. 11-12). In the illustrated example, support plates 1355-1, 1355-2 are secured to diaphragm screws 1354 above and below dome load diaphragm 1359 by nuts 1356, further supporting the diaphragm. The upper dome housing shell member 1351-1 includes a pressure port 1353 that supplies pressurized fluid at a set pressure (e.g., from a secondary pressure regulator) to the dome chamber and applies a corresponding load force against the dome load diaphragm 1359, moving the diaphragm screw 1354 against the piston member 1382 of the piston sensing mechanism 1380 (e.g., the pressure reducing regulator piston sensing mechanism 980 of FIG. 11 or the back pressure regulator diaphragm sensing mechanism 1080 of FIG. 12).

[0066] The pressure regulator may be provided with a self-venting feature that may be configured to reduce outlet pressure in the pressure-reducing regulator when the regulator's setpoint is lowered and no flow is available through the regulator. The self-venting feature may include a vent passage through a sensing element (e.g., a diaphragm screw in a diaphragm sensing element or a piston member in a piston sensing element) and a vent passage through the regulator valve body. According to one aspect of the present disclosure, a vent adapter block or plate may be assembled with the regulator valve body in combination with the use of a vent sensing element to provide this self-venting feature.

[0067] In the embodiment shown in FIG. 16, the vent diaphragm sensing mechanism 1480 includes a flat, flexible disk of material (e.g., an elastomer, plastic, or metal suitable for the system fluid) forming a diaphragm 1481 having an outer periphery clamped or secured by a threaded arrangement between the opposing surface of the valve body housing block 1415 and the opposing surface of a vent adapter block 1490 mounted between the valve body housing block and the load mechanism housing 1451 (e.g., a spring housing or dome housing). As shown, the vent diaphragm sensing mechanism 1480 can include a vent diaphragm screw 1482 threaded through a central opening in the diaphragm 1481, the diaphragm screw including a vent passage 1482-1 extending from the lower end surface of the diaphragm to the middle of the diaphragm screw, the vent passage aligning with a cavity 1491 in a vent adapter block 1490 and fluidly communicating with a vent port 1492 in the vent adapter block 1490. The vent port 1492 can be threaded for connection to a fluid path for containment and / or analysis of the vent fluid. The vent diaphragm screw 1482 can include a plastic (e.g., PEEK) relief valve seat 1482-2 to facilitate sealing engagement with the upper poppet stem 141 at pressures below the regulator setpoint.

[0068] 17, the vent 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 top of the piston member received through a central bore of a vent adapter block 1590. The piston adapter plate 1583 and vent adapter block 1590 are secured together, for example, by a threaded arrangement, between the disc housing block 1515 and the load mechanism housing 1551 (e.g., a spring housing or dome housing). As shown, the vent piston sensing mechanism 1580 can include a vent piston member 1582 positioned to have a vent passage 1582-1 extending from a bottom end surface of the piston member to a middle portion of the piston member, the vent passage 1582-1 aligning with a cavity 1591 in the vent adapter block 1590 and in fluid communication with a vent port 1592 in the vent adapter block. The vent port 1592 may be threaded for connection to a fluid path for containment and / or analysis of the vent fluid. The vent diaphragm screw 1582 may include a plastic (e.g., PEEK) relief valve seat 1582-2 to facilitate sealing engagement with the upper poppet stem 141 at pressures below the regulator setpoint.

[0069] For many of the exemplary features and embodiments described herein, regulator components may be adapted for use in multiple regulator configurations, e.g., to reduce the number of components required to construct various regulators. For example, as described herein, a modular regulator disc housing may be configured for use with both a pressure-reducing regulator assembly and a back-pressure regulator assembly (e.g., by providing a guide ring in the disc cavity to support the upper poppet stem of the pressure-reducing regulator assembly and by selectively orienting the seat carrier 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, a modular regulator disc housing may be configured for use with both a diaphragm-sensing configuration and a piston-sensing configuration (e.g., by assembling a piston adapter block or plate with the disc housing to accommodate the piston-sensing configuration). Additionally or alternatively, the modular regulator valve body housing may be configured to be used as both a non-vented assembly and a self-vented assembly (e.g., by assembling a vent adapter block with the valve body housing to provide self-venting capability in addition to installing a vented piston member / diaphragm screw).

[0070] 18-20 illustrate an exemplary piston sensing, self-venting, spring loaded pressure reducing regulator assembly 2000-1 including a valve disc module 2100 having a valve disc housing block 2110 and plug 2120 that retain or house a pressure reducing poppet 2130 and valve seat 2140 arrangement, a piston module 2200 having a piston adapter block 2210 that retains or houses a piston sensing member 2220 engaged with the poppet, a self-vent module 2300 having a vent adapter block 2310 that defines a vent port 2311 in fluid communication with a vent passage 2221 in the piston sensing member, and a spring loaded module 2400 having a load block 2410 that retains a spring loaded mechanism (e.g., the spring loaded mechanism shown in FIG. 13 and described above). The modular assembly blocks 2100, 2200, 2300, 2400 are provided with holes 2109, 2209, 2309, 2409 (e.g., spaced around the periphery as shown) that are aligned to receive elongated bolts 2009 that secure the blocks together as a single assembly.

[0071] To accommodate different modular configurations in which one or both of the piston module 2200 and the self-vent module are omitted, so that a uniform mating / sealing configuration can be provided between the stacked modular blocks 2110, 2210, 2310, 2410, the regulator assembly may be varied or provided as follows: 21, by omitting the piston module 2200 and assembling the disc housing block 2110 directly to the vent adapter block 2310, a diaphragm sensing vent assembly 2000-2 (with the diaphragm subassembly 2250 located within the cavity defined between the disc housing block and the vent adapter block); a piston sensing non-vented assembly 2000-3 by omitting the vent module 2300 and assembling the piston adapter block 2210 directly to the load block 2410, as shown in FIG. 22; or Diaphragm sensing non-vented assembly 2000-4 (with diaphragm subassembly 2250 located in a cavity defined between the disc housing block and the vent adapter block) by omitting both the piston module 2200 and the vent module 2300 and assembling the disc housing block 2110 directly to the load block 2410, as shown in FIG. 23.

[0072] A variety of uniform first and second block assembly interfaces can be used for uniform mating and sealing engagement between adjacent blocks. In an exemplary embodiment, as shown in FIG. 19 , the disc housing block 2110, the piston adapter block 2210, and the vent adapter block 2310 are each provided with a first assembly interface including a uniformly sized upper trepan seal groove 2115, 2215, 2315 recessed from the top surface counterbore 2114 or groove 2214, 2314 to accommodate the annular gasket seal 2106, 2206, 2306. The piston adapter block 2210, the vent adapter block 2310, and the load block 2410 each include a corresponding second assembly interface including a uniformly sized lower annular shoulder 2217 or rib 2317, 2417 that is received in a corresponding counterbore 2114 or groove 2214, 2314 and sealingly compresses the annular gasket seal 2106, 2206, 2306.

[0073] As shown in FIGS. 21 and 23, the diaphragm sensing assemblies 2000-2, 2000-4 may include a diaphragm 2251 having an outer periphery (e.g., a flange) 2256 that, when compressed between a trephine seal groove and a boss / rib (e.g., in combination with or instead of a gasket seal 2106), provides a seal between the disc housing block 2110 and the diaphragm 2251, and between the disc housing block and an adjacent vent adapter block (FIG. 21) or load block (FIG. 23).

[0074] Additionally, alternative load modules (e.g., the dome load module shown in FIG. 14 or the sensitive spring / dome load modules shown in FIGS. 9, 10, and 15) may be provided with similar lower annular bosses or ribs for assembly with the same valve body housing, piston adapter, and vent adapter blocks 2110, 2210, 2310.

[0075] 23, the exemplary pressure reducing regulator disc module 2100 includes a guide ring 2170 (e.g., similar to guide ring 170 described above) mounted within an enlarged upper recess 2118 of the disc housing block 2110 to closely receive the upper poppet stem of the pressure reducing poppet 2130. To convert or otherwise provide the regulator assembly as a backpressure regulator assembly 2000-4a, as shown in FIG. 24, the guide ring 2170 may be removed, allowing the enlarged upper recess 2118 of the disc housing block 2110 to accommodate the larger upper poppet stem of the backpressure poppet 2130a mounted in combination with the backpressure valve seat 2140a and diaphragm backpressure subassembly 2250a.

[0076] As shown, the modular regulator assembly of Figures 18-24 may include components and features more fully described above in the description of the embodiment of Figures 3-17.

[0077] Aspects of the present invention have been described with reference to exemplary embodiments. Modifications and alterations will occur to others upon reading and understanding this specification. This specification is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims

1. 1. A valve assembly comprising: A valve body, a body housing defining a first end port, a second end port, and a central cavity, the central cavity extending from a lower end of the body housing to an upper end of the body housing; a body plug assembled with the central cavity of the body housing and defining a flow passage between the first end port and the second end port; a valve body including: a valve seat carrier subassembly disposed within the body housing and secured between an end face of the body plug and a body counterbore in the central cavity, the valve seat carrier subassembly including first and second ring components assembled on an O-ring seal, a seat sealing portion of the O-ring seal exposed within an inner diameter gap between inner edges of the first and second ring components to define a valve seat seal; a poppet assembled with the valve disc and axially movable within the central cavity of the body housing between a closed position and an open position, wherein in the closed position a radially extending sealing surface of the poppet seals against the valve seat seal to prevent fluid from flowing through the axial extension of the flow passage, and in the open position a poppet sealing surface of the poppet axially separates from the valve seat seal to allow fluid to flow between the first end port and the second end port; 1. A valve assembly comprising: the first ring component and the second ring component are axially compressible against the O-ring seal to crush a seat sealing portion of the O-ring seal through an inner diameter gap between the first ring component and the second ring component.

2. 2. The valve assembly of claim 1, wherein the first ring component includes a radially inwardly extending flange defining an internal counterbore and an axially upwardly extending flange defining an external counterbore, and the second ring component includes an outer periphery seated within the external counterbore of the first ring component and an axially downwardly extending flange extending toward the radially inwardly extending flange of the first ring component to define an annular cavity for the O-ring seal and the inner diameter gap.

3. The valve assembly of claim 2 , wherein the internal counterbore and the external counterbore are radially oriented to form a stepped configuration.

4. 3. The valve assembly of claim 2, wherein an outer periphery of the second ring component comprises a radially outermost portion of the second ring component, the outer periphery being received within the external counterbore.

5. The valve assembly of claim 1 , wherein the valve seat carrier subassembly is secured between an upper end face of the body plug and the body counterbore.

6. The valve assembly of claim 5 , wherein the seat carrier subassembly includes a gasket seal in sealing engagement with the body counterbore.

7. 10. The valve assembly of claim 1, further comprising an actuator assembled with the valve disc for moving the poppet between the open and closed positions.

8. 8. The valve assembly of claim 7, wherein the actuator includes a loading mechanism configured to bias the poppet toward one of the open and closed positions; and a sensing mechanism in fluid communication with the first end port configured to move relative to the loading mechanism when fluid pressure in the first end port exceeds a set pressure to allow movement of the poppet to the other of the open and closed positions.

9. 2. The valve assembly of claim 1, wherein the poppet sealing surface is an upwardly facing sealing surface.

10. 2. The valve assembly of claim 1, wherein the poppet sealing surface is a downward facing sealing surface.

11. a valve seat carrier subassembly for a valve, the valve seat carrier subassembly comprising a first ring component and a second ring component assembled on an O-ring seal, a seat sealing portion of the O-ring seal exposed within an inner diameter gap between inner edges of the first ring component and the second ring component to define a valve seat seal; the first ring component and the second ring component are axially compressible against the O-ring seal to crush a seat sealing portion of the O-ring seal through an inner diameter gap between the first ring component and the second ring component.

12. 12. The valve seat carrier subassembly of claim 11, wherein the first ring component includes a radially inwardly extending flange defining an internal counterbore and an axially upwardly extending flange defining an external counterbore, and the second ring component includes an outer periphery seated within the external counterbore of the first ring component and an axially downwardly extending flange extending toward the radially inwardly extending flange of the first ring component to define an annular cavity for the O-ring seal and the inner diameter gap.

13. The valve seat carrier subassembly of claim 11 , wherein the valve seat seal faces a first side of the valve seat carrier subassembly.

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

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

16. a valve seat carrier subassembly for a valve, the valve seat carrier subassembly comprising a first ring component and a second ring component assembled on an O-ring seal, a seat sealing portion of the O-ring seal exposed within an inner diameter gap between inner edges of the first ring component and the second ring component to define a valve seat seal; the first ring component includes a radially inwardly extending flange defining an internal counterbore and an axially upwardly extending flange defining an external counterbore, and the second ring component includes an outer periphery seated within the external counterbore of the first ring component and an axially downwardly extending flange extending toward the radially inwardly extending flange of the first ring component to define an annular cavity for the O-ring seal and the inner diameter gap.

17. The valve seat carrier subassembly of claim 16 , wherein the internal counterbore and the external counterbore are radially oriented to form a stepped configuration.

18. 17. The valve seat carrier subassembly of claim 16, wherein an outer periphery of the second ring component comprises a radially outermost portion of the second ring component, the outer periphery being received within the external counterbore.

19. 17. The valve seat carrier subassembly of claim 16, wherein the first ring component and the second ring component are axially compressible against the O-ring seal to crush a seat sealing portion of the O-ring seal through an inner diameter gap between the first ring component and the second ring component.

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