Spring return valve handle mechanism

Abstract

A spring return cartridge for a rotary actuated valve includes a torsion spring having a spring load intermediate portion extending between a first end and a second end, and a spring carrier covered by the torsion spring. The spring carrier includes a first portion rotatably fixed to the first end of the torsion spring and a second portion rotatably coupled to the second end of the torsion spring. The second portion of the torsion spring is rotatable relative to the spring carrier and relative to the first end of the torsion spring between a first rotational limit position and a second rotational limit position. The intermediate portion of the torsion spring biases the second end of the torsion spring to the first rotational limit position and maintains a spring loaded state at the first rotational limit position.

Description

Technical Field

[0001] Reference to Related Applications This application claims priority and all benefits to U.S. Provisional Patent Application No. 63 / 390,683 (SPRING RETURN VALVE HANDLE WITH PRELOADED SPRING RETURN SUBASSEMBLY), filed on July 20, 2022, and U.S. Provisional Patent Application No. 63 / 494,261 (SPRING RETURN VALVE HANDLE ARRANGEMENTS), filed on April 5, 2023, the entire disclosure of each of which is incorporated herein by reference.

Background Art

[0002] The present disclosure relates to a spring return handle. More specifically, the present disclosure relates to a spring return valve handle for a rotary actuated valve.

[0003] Manually operated flow control valves are used in many applications. As an example, a glove sample panel with a primary process line includes a manually operated sampling valve for selectively dispensing a sample of the process fluid into a sample container or bottle. In such applications, if the operator is unable to fully close the valve (e.g., by manually rotating the valve handle to the closed position), unwanted fluid release can occur, posing safety issues, contamination, and production losses.

Summary of the Invention

[0004] According to an exemplary aspect of one or more inventions presented in the present disclosure, a spring return cartridge includes a torsion spring having a spring load intermediate portion extending between a first end and a second end, and a spring carrier covered by the torsion spring. The spring carrier includes a first portion rotationally fixed to the first end of the torsion spring and a second portion rotatably coupled to the second end of the torsion spring, and the second portion of the torsion spring is rotatable relative to the spring carrier and relative to the first end of the torsion spring between a first rotational limit position and a second rotational limit position. The intermediate portion of the torsion spring biases the second end of the torsion spring to the first rotational limit position and maintains a spring loaded state at the first rotational limit position.

[0005] In some embodiments, the first end of the torsion spring includes at least one fastener hole aligned with a corresponding fastener hole in the first portion of the spring carrier, and a fastener is installed through the aligned fastener holes to rotationally fix the first end of the torsion spring to the first portion of the spring carrier.

[0006] In some embodiments, the second end of the torsion spring includes at least one fastener hole aligned with a corresponding slot in the second portion of the spring carrier, and the fastener is installed in the fastener hole and extends through the slot to rotatably fix the second end of the torsion spring to the second portion of the spring carrier.

[0007] In some embodiments, the first end of the torsion spring includes a first end collar providing one or more attachment points to the first portion of the spring carrier.

[0008] In some embodiments, the first end collar is integrally formed with the intermediate portion of the torsion spring.

[0009] In some embodiments, the second end of the torsion spring includes a second end collar providing one or more attachment points to the second portion of the spring carrier.

[0010] In some embodiments, the second end collar is integrally formed with the middle portion of the torsion spring.

[0011] In some embodiments, the torsion spring is enclosed by a spring carrier.

[0012] In some embodiments, the spring load intermediate portion, the first end, and the second end of the torsion spring are formed as a monolithic component.

[0013] In some embodiments, the spring carrier is assembled with the torsion spring.

[0014] In some embodiments, the torsion spring comprises a helical spring.

[0015] In some embodiments, the torsion spring comprises a spiral spring.

[0016] In some embodiments, the first portion of the spring carrier includes the lower end of the spring carrier, and the second portion of the spring carrier includes the upper end of the spring carrier.

[0017] In some embodiments, the spring carrier is integrally formed with the torsion spring.

[0018] In some embodiments, the torsion spring includes a spiral spring, the first end of the torsion spring includes the outer radial portion of the spiral spring, and the second end of the torsion spring includes the inner radial portion of the spiral spring.

[0019] In some embodiments, the second end of the torsion spring includes a shaft surrounded by the spring load intermediate portion of the torsion spring.

[0020] In some embodiments, the spring carrier includes an inner circumferential first interlock portion, the shaft includes an outer circumferential second interlock portion radially aligned with the first interlock portion, and the first interlock portion and the second interlock portion engage with each other to define a first rotational limit position and a second rotational limit position of the second end of the torsion spring.

[0021] In some embodiments, the first interlock portion includes at least one radially inwardly extending protrusion, and the second interlock portion includes at least one arcuate recess for receiving the at least one radially inwardly extending protrusion.

[0022] In some embodiments, the at least one radially inwardly extending protrusion includes a pin attached through a hole in the second portion of the spring carrier.

[0023] In some embodiments, the shaft includes a lower bore portion for receiving the valve stem of a rotary actuated valve when the spring return cartridge is installed in the rotary actuated valve.

[0024] In some embodiments, the shaft includes an upper stem extension configured for attachment to a valve handle.

[0025] In some embodiments, the shaft includes an upper bore portion for receiving the stem extension, and the stem extension is configured for attachment to a valve handle.

[0026] In some embodiments, the spring return cartridge further includes a stem extension installed in the upper bore portion.

[0027] In some embodiments, the spring return cartridge is fixed to the shaft and further includes a cover plate covering the upper ends of the spring carrier and the torsion spring.

[0028] According to one or more exemplary aspects of the invention presented in this disclosure, a spring return cartridge includes a torsion spring having an outer radial first end and an inner radial second end, a spring carrier surrounding the torsion spring and rotationally fixed to the outer radial first end, and a shaft surrounded by the torsion spring and rotationally fixed to the inner radial second end.

[0029] In some embodiments, the spring carrier is rotatably coupled to the shaft such that the shaft is rotatable relative to the spring carrier between a first rotational limit position and a second rotational limit position, and the torsion spring biases the shaft to the first rotational limit position and maintains the spring loading state at the first rotational limit position.

[0030] In some embodiments, the spring carrier is formed integrally with the torsion spring.

[0031] In some embodiments, the shaft is formed integrally with the torsion spring.

[0032] In some embodiments, the spring carrier includes an inner circumferential first interlock portion, the shaft includes an outer circumferential second interlock portion radially aligned with the first interlock portion, and the first interlock portion and the second interlock portion engage with each other to define a first rotational limit position and a second rotational limit position of the second end of the torsion spring.

[0033] In some embodiments, one of the first interlock portion and the second interlock portion includes at least one radially extending protrusion, the other of the first interlock portion and the second interlock portion includes at least one arcuate recess for receiving the at least one radially extending protrusion, and the at least one arcuate recess is shaped to define the first rotational limit position and the second rotational limit position.

[0034] In some embodiments, at least one radially extending protrusion includes a pin attached through a hole in the spring carrier.

[0035] In some embodiments, at least one radially extending protrusion is formed integrally with the spring carrier.

[0036] In some embodiments, the shaft includes a lower bore portion for receiving the valve stem of a rotary actuated valve when a spring return cartridge is installed in the rotary actuated valve.

[0037] In some embodiments, the shaft includes an upper bore portion for receiving a stem extension, which is configured for attachment to a valve handle.

[0038] In some embodiments, the spring return cartridge further includes a stem extension installed in the upper bore portion.

[0039] In some embodiments, at least one of the stem extension and the upper bore portion includes a ribbed surface providing press fit retention of the stem extension with the shaft.

[0040] In some embodiments, the spring return cartridge is fixed to the shaft and further includes a cover plate covering the upper ends of the spring carrier and the torsion spring.

[0041] In some embodiments, the shaft includes an upper stem extension configured for attachment to a valve handle.

[0042] In some embodiments, the spring carrier, the torsion spring, and the shaft are formed as monolithic components.

[0043] In some implementation modes, the spring carrier, the torsion spring, and the shaft are formed using additive manufacturing.

[0044] According to one or more other exemplary aspects of the inventions presented in this disclosure, a spring return handle mechanism includes a spring return cartridge (e.g., a spring return cartridge including one or more of the above features), a valve handle grippable by a user, and a stem. The spring return cartridge includes a torsion spring having a spring load intermediate portion extending between a first end and a second end, and a spring carrier covered by the torsion spring and rotationally fixed to the first end of the torsion spring and having a first portion attachable to a valve body of the valve and a second portion rotatably coupled to the second end of the torsion spring. The stem is insertable through the spring return cartridge and includes an end attachable to the valve handle and a stem interlock portion configured to engage with a spring interlock portion on the second end of the torsion spring.

[0045] In some embodiments, the stem interlock portion includes a shoulder surface and the spring interlock portion includes a counterbore surface of complementary shape for mating with the shoulder surface.

[0046] In some embodiments, the shoulder surface and the counterbore surface include grooved surfaces that engage with each other.

[0047] In some embodiments, the shoulder surface and the counterbore surface include knurled surfaces.

[0048] In some embodiments, the mechanism further includes a nut configured to be threadable onto the stem end and tightened against the spring interlock portion to maintain an interlock engagement between the spring interlock portion and the stem interlock portion.

[0049] In some embodiments, the stem includes a stem extension having a lower bore configured to receive a valve stem of the valve.

[0050] According to one or more other exemplary aspects of the inventions presented in this disclosure, a valve assembly includes a valve having a valve body and a rotatable valve stem extending from the valve body, and a spring return handle mechanism (e.g., a spring return handle mechanism including any of the above-described features), wherein a first portion of the spring carrier is assembled with the valve body, and a second end of the torsion spring is assembled with and rotationally fixed to the valve stem.

[0051] In some embodiments, the valve body includes a bonnet portion, and the first portion of the spring carrier is assembled with the bonnet portion.

[0052] In some embodiments, the first portion of the spring carrier is threadably assembled with the bonnet portion.

[0053] In some embodiments, the valve assembly further includes a stem extension assembled with the valve stem.

[0054] In some embodiments, the stem extension includes a lower bore that receives the valve stem.

[0055] According to one or more other exemplary aspects of the inventions presented in this disclosure, a method for assembling a preloaded spring return cartridge is provided. In an exemplary method, a torsion spring is covered with a spring carrier. A first end of the torsion spring is rotationally fixed to a first portion of the spring carrier. A second end of the torsion spring is rotated to a preloaded first rotational position. The second end of the torsion spring is rotatably fixed to a second portion of the spring carrier at the preloaded first rotational position.

[0056] According to another exemplary aspect of one or more of the present inventions presented in the present disclosure, a method for installing a preloaded spring return cartridge and a valve handle on a valve having a valve body and a stem extending from the valve body is provided. In an exemplary method, with the stem in a desired spring return rotational position, the stem is inserted through a central bore of the spring return cartridge. A spring interlock portion of the spring return cartridge is fitted and fixed to a stem interlock portion of the stem. The valve handle is assembled with the stem.

[0057] According to another exemplary aspect of one or more of the present inventions presented in the present disclosure, a method for preloading a spring return cartridge for a rotary actuated valve is provided, the spring return cartridge comprising a torsion spring having an outer radially first end and an inner radially second end, a spring carrier surrounding the torsion spring and rotationally fixed to the outer radially first end, and a shaft surrounded by the torsion spring and rotationally fixed to the inner radially second end. In an exemplary method, the shaft is rotated relative to the spring carrier to a first rotational limit position where the torsion spring is in a spring loaded state. An inner circumferential first interlock portion of the spring carrier is engaged with an outer circumferential second interlock portion of the shaft to fix the shaft at the first rotational limit position. The first interlock portion and the second interlock portion are configured to allow rotation of the shaft up to a second rotational limit position defined by the engagement of the first interlock portion and the second interlock portion, and the spring loaded torsion spring is configured to bias the shaft towards the first rotational limit position.

[0058] In some embodiments, one of the first interlock portion and the second interlock portion includes at least one radially extending protrusion, and the other of the first interlock portion and the second interlock portion includes at least one arcuate recess for receiving the at least one radially extending protrusion, the arcuate recess being shaped to define the first rotational limit position and the second rotational limit position.

[0059] In some embodiments, at least one radially extending protrusion includes a pin attached through a hole in the spring carrier.

[0060] In some embodiments, at least one radially extending protrusion is formed integrally with the spring carrier.

Brief Description of the Drawings

[0061]

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[0062] This detailed description merely describes exemplary embodiments and is not intended to limit the claims in any way. Indeed, the claimed invention is broader than the exemplary embodiments and is not limited thereby, and the terms used in the claims have their ordinary meaning. For example, the exemplary embodiments illustrated herein describe a spring return valve handle mechanism for a quarter turn ball valve, but the features of the present disclosure may additionally or alternatively be applied to other types of manually actuated valves (e.g., plug valves, needle valves, diaphragm valves, etc.), other rotary handle operated devices (e.g., electromechanical switch operated devices), or devices having a handle operable over a different range of motion (e.g., half turn or 180°, three-quarter turn or 270°, or any other suitable degree of rotation).

[0063] Although various aspects, concepts, and features of the present invention may be described and illustrated herein as embodied in exemplary embodiments in combination, these various aspects, concepts, and features may be used individually or in various combinations and sub - combinations in many alternative embodiments. Unless explicitly excluded herein, all such combinations and sub - combinations are intended to be within the scope of the present invention. Unless explicitly excluded herein, all such combinations and sub - combinations are intended to be within the scope of the present invention. Further, various alternative embodiments regarding the present invention's various aspects, concepts, and features may be described herein, such as alternative materials, structures, configurations, methods, circuits, devices and components, alternatives regarding formation, adaptation, and function, etc., but such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether currently known or later developed. One of ordinary skill in the art can readily adopt one or more of the aspects, concepts, or features of the present invention for additional embodiments and uses within the scope of the present invention even if such embodiments are not explicitly disclosed herein. Further, although some features, concepts, or aspects of the present invention may be described herein as a preferred mechanism or method, such a description is not intended to suggest that such a feature is required or necessary unless explicitly stated as such. Additionally, for the purpose of aiding in the understanding of the present disclosure, exemplary or representative values and ranges may be included, but such values and ranges should not be construed in a limiting sense and are intended to be critical values or ranges only if explicitly stated as such. A parameter identified as "approximately" or "about" a specified value is intended to include the specified value, values within 5% of the specified value, and values within 10% of the specified value, unless otherwise specified. Further, the accompanying drawings of the present disclosure are not essential but may be to scale and can thus be understood as teaching various ratios and proportions apparent in the drawings.Furthermore, although various aspects, features, and concepts may be explicitly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather, aspects, concepts, and features of the invention may be present herein that are fully described herein without being explicitly identified as such or as part of a particular invention. Instead, the invention is defined by the appended claims. The description of an exemplary method or process is not limited to including all steps as being necessary in all cases, nor is the order in which steps are presented to be construed as necessary or essential unless explicitly stated otherwise.

[0064] In many applications, it may be desirable to provide a mechanism to ensure that a manually operated valve returns to a desired state (e.g., a closed state) when a manual actuator (e.g., a handle) is released by an operator, for example, to prevent an unwanted fluid flow. Such mechanisms are often referred to as "deadman" handles. An exemplary mechanism for a spring return handle is disclosed in co-owned U.S. Patent No. 11,698,144, entitled SPRING RETURN VALVE HANDLE, the entire disclosure of which is incorporated herein by reference.

[0065] According to an exemplary aspect of the present disclosure, a spring return handle mechanism comprises a preloaded spring return cartridge (e.g., a subassembly or a monolithic component) configured to be assembled with a valve stem, and applies a spring-loaded rotational force to the valve stem to return the valve stem to a first rotational limit position.

[0066] In an exemplary mechanism, as schematically shown in FIG. 1, a preloaded spring return cartridge 10 includes a torsion spring (e.g., a helical or spiral spring) 20 covered by a spring carrier 30. A first (e.g., lower or outer radial) end 21 of the torsion spring 20 is rotationally fixed to a first portion (e.g., lower end) 31 of the spring carrier 30, and a second (e.g., upper or inner radial) end 22 of the torsion spring is rotatably coupled to a second portion (e.g., upper end) 32 of the spring carrier, whereby the second end of the torsion spring is rotatable relative to the spring carrier and relative to the first end of the torsion spring by a torsional or twisting movement of an intermediate or central (e.g., coiled) portion 23 of the torsion spring between a first rotational position and a second rotational position. The second end 22 of the torsion spring 20 may be fixed to the second portion 32 of the spring carrier 30 with the intermediate spring portion 23 preloaded or energized, whereby the second end of the torsion spring is held in the first rotational position with no rotational force applied to the second end of the torsion spring. In the illustrated embodiment, the spring carrier 30 is a hollow (e.g., tubular) housing or sleeve component that surrounds the torsion spring 20. In other embodiments (not shown), the spring carrier may be surrounded by the torsion spring and still provide for rotational fixation of the first end of the torsion spring and rotatable attachment to the second end of the torsion spring. As used herein, "sleeved with" includes an arrangement where a first component is surrounded by a second component ("sleeved within") and an arrangement where a first component surrounds a second component ("sleeved around").

[0067] To rotationally fix the first end 21 of the torsion spring 20 to the first part 31 of the spring carrier 30, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the first end 21 of the torsion spring 20 may be fixed to the first part 31 of the spring carrier 30 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. As an example, the first end of the torsion spring may be provided with one or more fastener holes or apertures that are aligned with corresponding fastener holes or apertures in the first part of the spring carrier, and through which fasteners (e.g., pins, machine screws, rivets, etc.) are attached to rotationally fix the first end of the torsion spring to the first part of the spring carrier.

[0068] To rotationally fix the second end 22 of the torsion spring 20 to the second part 32 of the spring carrier 30, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the second end 22 of the torsion spring 20 may be fixed to the second part 32 of the spring carrier 30 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. As an example, the second end of the torsion spring may be provided with one or more fastener holes or apertures that are aligned with corresponding slots or notches in the second part of the spring carrier, and through which fasteners (e.g., pins, machine screws, rivets, etc.) are attached to rotatably fix the second end of the torsion spring to the first part of the spring carrier.

[0069] The preloaded spring return cartridge may be used with various devices, for example, including a rotary valve assembly. As shown, the spring return cartridge may include a central bore sized to receive the valve stem therethrough to rotationally fix the valve stem to the rotatable spring-biased second end 22 of the torsion spring 20.

[0070] FIG. 2 schematically shows a preloaded spring return cartridge 10 assembled with an exemplary rotary valve 50 and a valve handle 90 for a user to operate the valve. The valve 50 includes a valve body 51 that defines an internal cavity 52 for holding a valve element 56 that is connected to or fixed to (e.g., integrated with or assembled with) a stem 70. The stem 70 extends from an upper bonnet portion 53 of the valve body 51 through a central bore of the spring return cartridge and is rotatable between a first position (e.g., a closed position, a reduced flow rate position, a first switching position) and a second position (e.g., an open position, an increased flow rate position, a second switching position) to adjust the position of the valve element 56. As shown in the figure, a first portion 31 of the spring carrier 30 is rotatably fixed to the valve body 51 (e.g., to the bonnet portion 53 of the valve body), and a second end 22 of the torsion spring 20 is rotatably fixed to an interlock portion 77 of the stem 70. The valve handle 90 is rotatably fixed to an end 78 of the stem 70 (e.g., attached through the valve handle and using a set screw tightened against a flat portion of the stem end), enabling a user to rotate the stem 70 and the second end 22 of the torsion spring from a first rotational position to a second rotational position by gripping and rotating the valve handle against the biasing force of, for example, the preloaded torsion spring 20. When the valve handle 90 is released, the second end 22 of the torsion spring, the stem 70, and the valve handle rotate by the biasing force of the spring and return to the first rotational position.

[0071] To rotationally fix the first part 31 of the spring carrier 30 to the valve body 51, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the first part 31 of the spring carrier 30 may be fixed to the valve body 51 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. As an example, the first part of the spring carrier may be provided with an internally threaded end, which is sized and configured to screw with an externally threaded part of the bonnet portion of the valve body.

[0072] To rotationally fix the second end 22 of the torsion spring 20 to the stem interlock portion 77, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the second end 22 of the torsion spring 20 may be fixed to the stem interlock portion 77 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. As an example, the second end of the torsion spring is provided with an internal counterbore surface having an interlocking mechanism (e.g., spline, groove, rough surface / high friction, or knurled surface) that meshes with a corresponding interlocking mechanism on the mating shoulder surface of the stem interlock portion.

[0073] The exemplary stem 70 has a length sufficient to accommodate the preloaded spring return cartridge 10 and the valve handle 90. The stem 70 can be formed as a unitary or monolithic stem component having integrally formed stem interlock 77 and end 78, although in some embodiments, the stem interlock 77 and end 78 may be provided on a separate stem extension (generally shown at 71) that can be fixed to a new or existing valve stem 55 to provide a retrofit installation of a spring return handle with, for example, an existing rotary actuated valve. The stem extension can be fixed to the valve stem using various arrangements including, for example, fasteners, clamps, keyed / splined connections, threading, and welding. In one such example, the stem extension can include a lower bore that receives the valve stem and a set screw that can be fixed at a flat portion of the valve stem to fix the stem extension against rotation and axial movement on the valve stem.

[0074] In some embodiments, according to an exemplary aspect of the present disclosure, the spring carrier may be assembled with a torsion spring and may be a separate component adapted to preload the torsion spring prior to assembly with the valve, for example, to facilitate installation on the valve.

[0075] Figures 3 and 4 show an exemplary embodiment of a preloaded spring return cartridge 110 that includes a torsion spring 120 and a spring carrier 130. A first (e.g., lower) end 121 of the torsion spring 120 is rotationally fixed to a first (e.g., lower end) portion 131 of the spring carrier 130, and a second (e.g., upper) end 122 of the torsion spring is rotatably coupled to a second (e.g., upper end) portion 132 of the spring carrier, such that the second end of the torsion spring is rotatable relative to the spring carrier and relative to the first end of the torsion spring between a first rotational position and a second rotational position by a torsional or twisting movement of an intermediate or central (e.g., coiled) portion 123 of the torsion spring. The second end 122 of the torsion spring 120 may be fixed to the second portion 132 of the spring carrier 130 with the intermediate portion 123 of the torsion spring preloaded or energized, such that the second end of the torsion spring is held in the first rotational position with no rotational force applied to the second end of the torsion spring.

[0076] For example, many different types of torsion spring elements, including one or more conventional coil spring components, may be used in the preloaded spring return cartridge. In an exemplary configuration, as shown in FIGS. 3 and 4, the torsion spring 120 may include an intermediate spring load coil portion 123 disposed between a first end cuff or collar 121 and a second end cuff or collar 122 that is fixed (e.g., fastened to, welded to, or integrally formed with) to the spring load portion. The first and second end collars 121, 122 can provide one or more attachment points to the spring carrier 130 and the stem 170, as will be described in more detail below. In the illustrated embodiment, the spring load coil portion 123 has a helical configuration. In other embodiments, the spring load portion may utilize other configurations, such as, for example, a spiral or clock-type spring configuration, similar to that shown in the embodiments of FIGS. 8A-9, which will be described in more detail below.

[0077] As shown in FIG. 3, the torsion spring may be a unitary or monolithic component, and the first and second end collars 121, 122 are formed integrally with and extend from a helical coil type intermediate spring load portion 123. As shown in the figure, the second end collar 122 may have an outer diameter that substantially matches the outer diameter of the intermediate spring load portion 123 of the torsion spring 120. As shown in the figure, using a machined torsion spring enables custom attachments such as the end collar attachments described herein, eliminating the need for additional torsional bearing connections between the spring, the stem, and the handle. As a result, the unitary spring may bias a "pure moment," meaning that the torsion spring does not bias translational (side load) forces. This may eliminate the need for one or more external stabilizing components that might otherwise be required.

[0078] To rotationally fix the first end 121 of the torsion spring 120 to the first portion 131 of the spring carrier 130, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the first end 121 of the torsion spring 120 may be fixed to the first portion 131 of the spring carrier 130 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. In some configurations, as shown in the illustrated embodiment, the first end collar 121 of the torsion spring 120 is provided with one or more fastener holes or apertures 124 that are aligned with corresponding fastener holes or apertures 134 of the first portion 131 of the spring carrier 130, through which a fastener 144 (e.g., a pin, machine screw, rivet, etc.) is attached to rotationally fix the first end of the torsion spring to the first portion of the spring carrier.

[0079] To rotatably fix the second end portion 122 of the torsion spring 120 to the second portion 132 of the spring carrier 130, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the second end portion 122 of the torsion spring 120 may be fixed to the second portion 132 of the spring carrier 130 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding portions. In some configurations, as shown in the illustrated embodiment, the second end collar 122 of the torsion spring 120 is provided with one or more fastener holes or apertures 125 that are aligned with corresponding notches or slots 135 in the second portion 132 of the spring carrier 130, through which a fastener 145 (e.g., a pin, machine screw, rivet, etc.) is attached to rotatably fix the second end of the torsion spring to the second portion of the spring carrier. The slot 135 may be sized to define the range of rotational movement of the second end portion 122 of the torsion spring with respect to the spring carrier 130 (and the valve to which the spring carrier is attached) (e.g., about 90° in the case of a quarter-turn valve), and corresponding to the engagement of the end(s) of the slot(s) 135 with the fastener(s) 145, provide the first (spring return) and second (user-actuated) limit positions of the second end of the torsion spring (and the stem to which the second end of the spring is attached).

[0080] In an exemplary method of assembling a preloaded spring return cartridge 110, the torsion spring 120 is inserted into or encapsulated within the spring carrier 130, and the fastener holes 124 of the first end collar 121 are aligned with the fastener holes 134 of the first portion 131 of the spring carrier. A spring pin 144 (or other suitable fastener) is installed through the aligned fastener holes 124, 134 to rotationally secure the torsion spring 120 and the first portions 121, 131 of the spring carrier 130. The second end collar 122 of the torsion spring 120 is rotated (e.g., counterclockwise) to align the fastener hole 125 within the second end collar 122 of the torsion spring with the slot 135 within the second portion 132 of the spring carrier. A lock pin 145 (or other suitable fastener) is installed in the fastener hole 124 at the second end of the torsion spring, extends through the slot 135 of the spring carrier, and is biased by the spring such that the lock pin engages the first end of the slot to maintain the preloaded or energized state of the coil portion 123 of the torsion spring at the first rotational position of the second end collar 122.

[0081] Figures 5 and 6A - 6D show an exemplary preloaded spring return cartridge 110 assembled with a rotary valve 150 and a valve handle 190 for actuation by a user of the valve. The valve 150 includes a valve body 151 that defines an internal cavity 152 that retains a valve element 156 that is coupled to or fixed to (e.g., integrated with or assembled with) a stem 170. While many different types of valve elements may be utilized, in the illustrated embodiment, the valve element includes a ball portion 156 that includes a ball orifice 154 that is misaligned with the first and second end ports 161, 162 within the valve body 151 in the closed position to block the passage of fluid through the valve 150 and is aligned with the end ports of the valve body in the open position to permit the passage of fluid through the valve.

[0082] The internal cavity 152 extends up to the upper bonnet portion 153 of the valve body 151 from which the stem 170 extends. The stem 170 is rotatable between a first position (e.g., a closed position, a reduced flow position, a first switching position) and a second position (e.g., an open position, an increased flow position, a second switching position) to adjust the position of the valve element 156.

[0083] In the illustrated embodiment, the valve 150 includes a valve seat and a stem sealing mechanism 165 within the valve cavity 152 to seal the valve against leakage of the valve seat and the stem. In other embodiments, other sealing mechanisms may be utilized. Further, the illustrated embodiment includes a valve closing or shut-off valve element, but other types of valve elements, such as a flow control valve element or a flow switching valve element, may also be used.

[0084] The bonnet portion 153 of the valve body 151 has an internal threaded portion 163 for assembling a stem nut 164 that retains the stem 170 to the valve body. The stem 170 includes an upper portion that extends beyond the bonnet portion 153 for attachment to a spring return handle mechanism 110, as described hereinafter.

[0085] As shown in the figure, a first portion 131 of the spring carrier 130 is rotatably fixed to the valve body 151 (e.g., to the bonnet portion 153 of the valve body), and a second end 122 of the torsion spring 120 is rotatably fixed to an interlock portion 177 of the stem 170. The valve handle 190 is rotatably fixed to an end 178 of the stem 170 (e.g., using a set screw that is attached through the valve handle 190 and tightened against a flat portion of the stem end 178), enabling a user to rotate the stem 170 and the second end 122 of the torsion spring from a first rotational position to a second rotational position by gripping and rotating the valve handle against the biasing force of the preloaded torsion spring 120. When the valve handle 190 is released, the second end 122 of the torsion spring, the stem 170, and the valve handle rotate by the biasing force of the spring to return to the first rotational position.

[0086] To rotationally fix the first portion 131 of the spring carrier 130 to the valve body 151, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the first portion 131 of the spring carrier 130 may be fixed to the valve body 151 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. In some configurations, as shown in the illustrated embodiment, the first portion 131 of the spring carrier 130 includes an internal female thread portion 136, which is sized to mate with and configured to mate with the external male thread portion 166 of the bonnet portion 153 of the valve body. As shown, the first portion 131 of the spring carrier 130 may be provided with a plurality of flat portions 137 to facilitate screw-type assembly (or disassembly) of the spring carrier with the valve body 151, for example, using a torque wrench or other such tool.

[0087] To rotationally fix the second end 122 of the torsion spring 120 to the stem interlock portion 177, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the second end 122 of the torsion spring 120 may include a spring interlock portion 127 fixed to the stem interlock portion 177 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding portions. In some configurations, as shown in the illustrated embodiment, the second end collar 122 of the torsion spring 120 includes an internal counterbore surface 129 having an interlock mechanism (e.g., spline, groove, rough surface / high friction, or knurled surface) that meshes with a corresponding interlock mechanism on the mating shoulder surface 179 of the stem interlock portion 177. As an example, laser engraved or machined ridges may be provided on the mating counterbore and shoulder surfaces 129, 179 to provide an interlock engagement. These interlock mechanisms may enable an interlock engagement between the stem 170 and the second end 122 of the spring in many, or almost any, relative rotational positions, for example, to provide a valve handle (e.g., the orientation on the valve stem may be limited) with a desired spring return orientation on the valve. The hex nut 167 can be detachably attached to the stem end 178 and tightened against the second end collar 122 of the torsion spring 120 to maintain an interlock engagement between the mating counterbore and shoulder surfaces 129, 179. As shown, the counterbore and shoulder surfaces 129, 179 may be substantially frustoconical, for example, to facilitate a secure interlock engagement between the surfaces when the hex nut 167 is fully tightened, but this is not essential.

[0088] The exemplary stem 170 has a length sufficient to accommodate the preloaded spring return cartridge 110 and the valve handle 190. The stem 170 can be formed as a unitary or monolithic stem component having an integrally formed stem interlock portion 177 and an end 178, but in some configurations, including the illustrated embodiment, the stem interlock portion 177 and the end 178 are provided on a separate stem extension 171 that can be fixed to the existing or new valve stem 155, for example, to provide a retrofit installation of a spring return handle with an existing rotary actuated valve. The stem extension 177 can be fixed to the existing valve stem using various arrangements including, for example, fasteners, clamps, keyed / splined connections, threading, and welding. In some configurations, as shown in the illustrated embodiment, the stem extension 171 includes a lower bore 172 that receives the valve stem 155 and a set screw 173 that can be fixed to the flat portion 168 of the valve stem 155. As shown in FIGS. 6A, 7A, and 7B, the lower bores 172, 172a can be provided in a keyed shape (e.g., triangular, semi-circular) to more firmly or robustly rotationally fix the stem extensions 171, 171a to the valve stem 155 for connecting and receiving the flat portion 168 of the valve stem 155. The stem extension 171 can include a larger diameter lower portion below the shoulder surface 179 and a smaller diameter upper portion above the shoulder surface that closely match the larger and smaller inner diameter portions of the central bore of the spring return cartridge 110.

[0089] In an exemplary method of installing a preloaded spring return cartridge 110 and valve handle 190 onto valve 150, as shown in FIGS. 5 and 6A - 6D, stem extension 171 is assembled with valve stem 155, and the flat portion 168 of valve stem 155 is inserted into the lower bore 172 of the stem extension (FIG. 6A), and a set screw 173 (or other suitable fastener) is tightened against the flat portion 168 of the valve stem. With the valve stem 155 in the desired "spring return" rotational position, the stem extension 171 is inserted through torsion spring 120 (FIG. 6B), whereby the shoulder surface 179 of the stem extension mates with the counterbore surface 129 of the second end collar 122 of the torsion spring. Hex nut 167 is threaded onto stem extension interlock portion 177 and tightened against the second end collar 122 of torsion spring 120 (FIG. 6C) to maintain the interlock engagement between the mating counterbore and shoulder surfaces 129, 179. Valve handle 190 is assembled with the flat portion of stem end 178 using a set screw 176 that is attached through valve handle 190 and tightened against the flat portion of stem end 178 (FIG. 6D).

[0090] In some embodiments, according to an exemplary aspect of the present disclosure, the spring carrier may be integrally formed with the torsion spring (e.g., as a surrounding sleeve or housing) and may be adapted to preload the torsion spring prior to assembly with the valve, for example, to facilitate installation onto the valve. Such a configuration may provide, for example, a smaller and more compact design.

[0091] Figs. 8A, 8B, and 8C illustrate an exemplary embodiment of a preloaded spring return cartridge 210, which includes a spring return cartridge element 211 having a spiral or clock-type torsion spring 220 formed integrally (e.g., by machining or additive manufacturing) with a spring carrier 230. A first (e.g., radially outer) end 221 of the torsion spring 220 is rotatably fixed to a first (e.g., upper inner diameter wall) portion 231 of the spring carrier 230, and a second (e.g., radially inner) end 222 of the torsion spring is rotatably coupled to a second (e.g., lower offset inner diameter wall) portion 232 of the spring carrier, such that the second end of the torsion spring is rotatable relative to the spring carrier and relative to the first end of the torsion spring by a torsional or twisting motion of an intermediate or central (e.g., coiled) portion 223 of the torsion spring between a first rotational position and a second rotational position. The second end 222 of the torsion spring 220 is rotatably fixed or engaged with the second portion 232 of the spring carrier 230 when the intermediate portion 223 of the torsion spring is preloaded or energized, such that the second end of the torsion spring is held in the first rotational position when no rotational force is applied to the second end of the torsion spring.

[0092] For example, many different types of torsion spring elements, including one or more conventional coil spring components, may be used in a preloaded spring return cartridge. In an exemplary configuration, as shown in FIGS. 8A and 8B, the torsion spring 220 is disposed between the outer radial starting portions 221 of the first end, integrally formed with the upper inner diameter wall portion 231 of the spring carrier 230, and may include an intermediate spring load coil portion 223 extending radially inward therefrom and a central shaft 222 integrally formed with the coil portion 223. The central shaft 222 can provide one or more attachment points to the valve stem and / or stem extension, as will be described in more detail below. The integrally formed construction of the torsion spring 220 and the spring carrier 230, and the use of a plurality of equally spaced spiral spring starting portions 221 (e.g., three starting portions as shown), can facilitate a "pure moment" biasing such that the torsion spring does not bias a translational (side load) force. This may potentially eliminate one or more external stabilizing components that might otherwise be required.

[0093] The spiral spring configuration of the torsion spring 220 may be adapted to provide an appropriate torque output to the spring load handle and valve stem, for example, by selecting the height of the spring (the height is greater when the torque output is large and smaller when the torque is small), or the number of starts of the spring (the number of starts increases as the torque output increases and decreases as the torque output decreases).

[0094] To rotatably secure the second inner radial shaft portion 222 of the torsion spring 220 to the second lower inner diameter offset portion 232 of the spring carrier 230, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, as shown in FIGS. 8B and 8C, the shaft 222 of the torsion spring 220 may include radially outwardly extending bearing portions 226a, 226b that define one or more arcuate recesses 228, and the lower inner diameter offset portion 232 of the spring carrier 230 may include one or more radially inwardly extending protrusions 235 that are received in corresponding arcuate recesses. As shown in the embodiments of FIGS. 8A-9, the protrusion 235 may be provided as a pin that is press-fitted or otherwise installed through a hole 238 in the lower offset portion 232. In other embodiments, the protrusion may be formed integrally with the spring carrier, as will be described in more detail below.

[0095] The recess 228 may be sized to define the range of rotational movement of the second end portion 222 of the torsion spring relative to the spring carrier 230 (and the valve to which the spring carrier is attached) (e.g., approximately 90° in the case of a quarter-turn valve), and corresponding to the engagement of the protrusion 235 with the bearing portions 226a, 226b that define the recess, provide the first (spring return) and second (user actuated) limit positions of the second end portion of the torsion spring (and the stem to which the second end portion of the spring is attached). In other embodiments (e.g., similar to the embodiments of FIGS. 3-6D), the inner diameter wall of the spring carrier may include an arcuate slot or recess that receives a radially extending protrusion from a central shaft so as to define the range of rotational movement of the second end portion of the torsion spring relative to the spring carrier.

[0096] In an exemplary method of preloading the spring return cartridge 210, the shaft 222 is rotated relative to the spring carrier 230 (e.g., from an unloaded orientation by at least about 90°) to a first rotational limit position where the coil portion 223 of the torsion spring is in a spring-loaded state (e.g., at or slightly beyond the first rotational limit position). One or more pins 235 are installed (e.g., press-fit) through radially extending holes 238 in a lower inner diameter offset portion 232 of the spring carrier 230. The spring-loaded intermediate portion 223 of the torsion spring 230 biases a bearing portion 226a that defines a first rotational limit of the central shaft 222 against the installed pins 235 to hold the preloaded spring shaft 222 in the first rotational limit position.

[0097] When a rotational force or torque that opposes the biasing force of the torsion spring is applied to the shaft 222, the rotation of the shaft is limited to the second rotational limit position by the engagement of the bearing portion 226b that defines the second rotational limit with respect to the installed pin 235. In some embodiments, the preloaded interlock mechanism of the spring return cartridge may be formed integrally with the spring carrier. For example, when the spring carrier cartridge element is preloaded, it may be elastically deformable during the preloaded rotation of the spring cartridge shaft for radial alignment with the arcuate recess. FIGS. 10A, 10B, and 10C show a bottom view of an exemplary spring return cartridge element 311 having fins or other such protrusions 335 extending radially inward from the lower offset portion 332 of the spring carrier and bearing portions 326a, 326b extending radially outward that define the arcuate recess 328. To preload the spring return cartridge element 311, the central shaft 322 rotates from the unloaded state (FIG. 10A) to the first rotational limit position (FIG. 10B) (i.e., clockwise in the figures shown in FIGS. 10A - 10C), and the protrusions 335 engage the bearing portions 326a, 326b and elastically deform to deviate from the radial alignment with the arcuate recess 328. Then, when the shaft is at the first rotational limit position, it elastically fits into the inside of the arcuate recess. At the first rotational limit position, the end 335a of the protrusion 335 engages the bearing portions 326a, 326b to fix the spring return cartridge element in the preloaded first rotational limit position. The shaft 322 is further rotatable from the first rotational limit position to a second rotatable limit position (FIG. 10C) against the torsional force of the spring loaded coil portion 323. The torsional limit of the torsion spring coil portion 323 may provide a positive stop at the second rotational limit position, but in other embodiments, other spring return cartridges, handles, and / or valve elements may define a positive stop at the second rotational limit position.

[0098] In other embodiments, the preloaded interlock mechanism of the spring return cartridge can be formed integrally with the central shaft. For example, when the spring carrier cartridge element is preloaded, it can be elastically deformable during the preload rotation of the spring cartridge shaft for radial alignment with the inner circumferential recess of the spring carrier. FIG. 11 shows a cross-sectional perspective view of an exemplary spring return cartridge element 411 having fins or other such protrusions 426 extending radially outward from the shaft 422 and bearing portions 435a, 435b, 435c extending radially inward from the lower offset portion 432 of the spring carrier to define an arcuate recess 438. To preload the spring return cartridge element 411, the central shaft 422 rotates from an unloaded state (FIG. 11A) to a first rotational limit position (FIG. 11B) (i.e., clockwise in the figures shown in FIGS. 11A - 11C), and the protrusion 426 engages the bearing portion 435 and flexes or elastically deforms inwardly out of radial alignment with the arcuate recess 438. Then, when the shaft is at the first rotational limit position, it elastically snaps into place outside the arcuate recess. At the first rotational limit position, the end 426a of the protrusion 426 engages the bearing portion 435 to fix the spring return cartridge element in the preloaded first rotational limit position. The shaft 422 is further rotatable from the first rotational limit position to a second rotatable limit position (FIG. 11C) against the torsional force of the spring load coil portion 423. The torsional limit of the torsion spring coil portion 423 can provide a positive stop at the second rotational limit position, but in other embodiments, other spring return cartridges, handles, and / or valve elements can define a positive stop at the second rotational limit position.

[0099] FIG. 9 shows the preloaded spring return cartridge 210 of FIGS. 8A-8C assembled with an exemplary rotary valve 250 and valve handle 290 for actuation by a valve user. The valve 250 and valve handle 290 can be assembled with the spring return cartridge elements 311, 411 of FIGS. 10A-11C using any one or more of the features described below, and any of the spring return cartridges and spring return cartridge elements can be assembled with a wide variety of valves and valve handles.

[0100] The valve 250 includes a valve body 251 that defines an internal cavity 255 that holds a valve element 256 that is connected to or fixed to (e.g., integral with or assembled with) a valve stem 255. Although many different types of valve elements can be utilized, in the illustrated embodiment, the valve element includes a ball portion 256 that includes a ball orifice 254 that is misaligned with first and second end ports 261, 262 in the valve body 251 in the closed position to block the passage of fluid through the valve 250 and is aligned with the end ports of the valve body in the open position to allow the passage of fluid through the valve.

[0101] The internal cavity 252 extends to an upper bonnet portion 253 of the valve body 251 from which the valve stem 255 extends. The valve stem 255 is rotatable between a first position (e.g., closed position, reduced flow position, first switching position) and a second position (e.g., open position, increased flow position, second switching position) to adjust the position of the valve element 256.

[0102] In the illustrated embodiment, the valve 250 includes a valve seat and stem seal mechanism 265 within the valve cavity 252 to seal the valve against valve seat and stem leakage. In other embodiments, other sealing mechanisms may be utilized. Further, the illustrated embodiment includes a valve closure or shut-off valve element, but other types of valve elements, such as a flow control valve element or a flow switching valve element, can be used.

[0103] The bonnet portion 253 of the valve body 251 has an internal thread portion 263 for assembling a stem nut 264 that holds the valve stem 255 in the valve body. The valve stem 255 includes an upper portion that extends beyond the bonnet portion 253 for attachment to a spring return handle mechanism 210, as will be described later. The valve stem can extend through a spring return cartridge for direct attachment to a valve handle, but in the illustrated embodiment, as will be described in more detail below, a stem extension 271 is attached to the valve stem 255 (e.g., by bore portions 229a, 229b of the shaft 222) to form an extended valve stem configuration.

[0104] As shown in the figure, a first portion 231 of the spring carrier 230 is rotatably fixed to the valve body 251 (e.g., to the bonnet portion 253 of the valve body), and a second end portion or shaft 222 of the torsion spring 220 is rotatably fixed to an interlock portion or lower end portion 277 of the stem extension 271. The valve handle 290 is rotatably fixed to the upper end portion 278 of the stem extension 271 (e.g., attached through the valve handle 290 and using a set screw tightened against a flat portion of the upper end portion 278 of the stem extension), enabling a user to rotate the valve stem and the second end portion or shaft 222 of the torsion spring from a first rotational position to a second rotational position by gripping and rotating the valve handle against the biasing force of, for example, a preloaded torsion spring 220. When the valve handle 290 is released, the shaft 222, the stem extension 271, and the valve handle 290 rotate by the biasing force of the spring to return to the first rotational position.

[0105] To rotationally fix the first part 231 of the spring carrier 230 to the valve body 251, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the first part 231 of the spring carrier 230 may be fixed to the valve body 251 using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. In some configurations, as shown in the illustrated embodiment, the first part 231 of the spring carrier 230 extends into a downwardly threaded collar portion 236, which is sized and configured to screw with an external threaded portion 266 of the bonnet portion 253 of the valve body. As shown, the collar portion 236 of the spring carrier 230 may be provided with a plurality of flat portions 237 to facilitate tightening the spring carrier to the valve body 251 using, for example, a torque wrench or other such tool. The set screw 225 is attached through the hole 239 of the threaded collar portion 236 to be able to fix the collar portion against an unexpected screw rotation of the spring return cartridge 210 on the valve body 251. The set screw 225 may be provided with a soft (e.g., brass) tip to minimize damage to the threads of the bonnet. In other embodiments, other configurations including split ring clamps or other clamping mechanisms, which are, for example, assembled with or integrally formed with the spring carrier, may be used to fix the spring return cartridge against rotation.

[0106] To rotationally fix the shaft 222 of the torsion spring 220 to the lower end portion 277 of the stem extension, many different arrangements may be used, either directly or using one or more intermediate attachment components. For example, the shaft 222 of the torsion spring 220 may include a spring interlock portion fixed to the lower end portion 277 of the stem extension using one or more fasteners, clamps, keyed / splined connections, screwing, and / or welding parts. In some configurations, as shown in the illustrated embodiment, the shaft 222 of the torsion spring 220 includes an internal upper bore portion 229a having an interlock mechanism (e.g., spline, groove, rough surface / high friction, or knurled surface) that meshes with the outer peripheral surface 279 of the lower end portion 277 of the stem extension. As an example, circumferentially spaced ribs or protrusions 224 may be provided in the internal bore 229a to facilitate a rotationally fixed press-fit engagement between the shaft 222 and the stem extension 271. These interlock mechanisms may enable an interlock engagement between the stem extension 271 and the shaft 122 in many, or almost any, relative rotational position, for example, to provide a valve handle (e.g., the orientation on the valve stem may be limited) in a desired spring return direction on the valve. In other embodiments (not shown), the stem extension may be rotationally fixed to the shaft by a complementary keyed cross-sectional shape of the stem extension end and the shaft upper bore portion. In yet another exemplary embodiment, the stem extension may be integrally formed with the shaft of the spring carrier, thereby eliminating the need for an attachment mechanism.

[0107] To protect the torsion spring 220 from moisture or other contamination, a cover plate 240 may be fixedly attached to cover the upper ends of the torsion spring and the spring carrier 230. In the illustrated example, the cover plate 240 includes a central hole 241 that receives the lower end 277 of the stem extension 271, and the shoulder 275 of the stem extension engages the cover plate to hold the cover plate against the upper ends of the torsion spring and the spring carrier. The cover plate 240 may be provided with a plastic material, for example, to reduce friction and noise from rotation against the upper ends of the torsion spring and the spring carrier. The cover plate may be provided with an outer peripheral wall or lip that covers the upper end of the spring carrier to provide further protection from, for example, the ingress of contamination.

[0108] The exemplary stem mechanism 270 has a length sufficient to accommodate the preloaded spring return cartridge 210 and the valve handle 290. The valve stem can be formed as a unitary or monolithic valve stem component with an integrally formed valve stem interlock and an end (not shown), but in some configurations, including the illustrated embodiment, the stem extension lower end 277 and the upper end 278 are, for example, new or existing valve stems 255 (e.g., by attachment to the shaft 222) to provide a retrofit installation of a spring return handle with an existing rotary actuated valve. The stem extension 271 can be provided on a separate stem extension 271 that can be fixed to the existing valve stem using various mechanisms including, for example, fasteners, clamps, keyed / splined connections, threading, and welding. In some configurations, as shown in the illustrated embodiment, the stem extension 271 is fixed at the upper bore portion 229a of the shaft 222 and the valve stem 255 is fixed at the lower bore portion 229b of the shaft. As shown, the lower bore portion 229b is provided in a keyed shape (e.g., triangular, semi-circular, single or double flat bore) to, for example, connect and receive the complementary shaped flat portion 268 of the valve stem 255, or to rotatably attach the shaft 222 to the valve stem 255 more firmly or robustly. By using the closely fitting complementary shaped flat stem 268 and the shaft lower bore portion 229b, play in handle rotation can be eliminated without the need for set screws or other fasteners.

[0109] To assemble the spring return handle mechanism, for example, for assembly after a rotary-actuated valve is provided, the stem extension 271 is installed by press-fitting, for example, the lower end 277 of the stem extension into the upper bore portion 229a of the spring return cartridge shaft 222, into the ribbed upper bore. The valve handle 290 is assembled with the upper end 278 of the stem extension 271, for example, by tightening a setscrew set 276 installed via the valve handle against the flat portion at the upper end of the stem extension. The stem extension 271 and the valve handle 290 can be assembled to the spring return cartridge 210 after preloading, but in other embodiments, the stem extension and the valve handle can be assembled to the spring return cartridge before preloading to apply a preload torque force to the shaft 222 using the valve handle.

[0110] In an exemplary method of installing a spring return handle mechanism to a valve 250, the upper flat portion 268 of the valve stem 255 is partially inserted into the lower stem bore portion 229b of the spring return cartridge shaft 222, and the spring carrier 230 is assembled threadably to the valve body bonnet portion 253, for example, by engaging the flat portion 237 of the spring carrier collar portion 236 using a wrench or other tool. During this threaded installation, the valve stem 255 rotates within the valve body 251. When the spring carrier 230 is fully threaded to the valve body bonnet portion 253, the spring carrier and the valve stem 255 are rotationally adjusted to a desired “spring return” rotational position (e.g., the fully closed position of the valve stem relative to the valve body 251), and the setscrew 225 within the spring carrier collar portion 236 is tightened against the valve body bonnet portion to secure the spring return cartridge against further rotation on the valve body 251. In some embodiments, the stem extension 271 and the valve handle 290 can be assembled to the spring return cartridge 230 after installation of the spring return cartridge onto the valve 250.

[0111] The overall shape and structural configuration of the monolithic spring return cartridge elements 211, 311, 411 can be difficult to manufacture the components using conventional machining, forming, or casting techniques. According to one aspect of the present disclosure, the spring return cartridge elements can be manufactured using additive manufacturing (e.g., 3D printing) to produce monolithic components having a desired integrally formed shaft, spring, and carrier configuration. Examples of available additive manufacturing techniques include, for example, laser powder bed fusion bonding (direct metal laser sintering or "DMLS", selective laser sintering / melting or "SLS / SLM", or laminated additive manufacturing or "LAM"), electron beam powder bed fusion bonding (electron beam melting or "EBM"), ultrasonic additive manufacturing ("UAM"), or direct energy deposition (laser powder deposition or "LPD", laser wire deposition or "LWD", laser engineered net shaping or "LENS", electron beam wire evaporation), binder jetting technology (BJT), mold slurry deposition (MSD), bound metal extrusion (BME), nanoparticle jetting technology (NPJ), etc., sintering-based additive manufacturing. By providing the spring return cartridge elements as a single monolithic component, the assembly cost can be reduced, component wear can be reduced, the adverse effects of thermal cycling can be mitigated, corrosion behavior (galvanic effect, crevice, stress corrosion cracking) can be improved, and the manufacturing lead time can be shortened. Further, manufacturing using additive manufacturing can reduce the amount of raw material used and can reduce the size and weight of the finished component. The spring return cartridge elements can be provided in any suitable material, including, for example, stainless steel.

[0112] As shown in the figures, the additive manufactured spring return cartridge elements 211, 311, 411 provide a spring carrier, a stem, and a torsion spring as unitary or monolithic components for assembly using a rotary actuated valve. In other embodiments, for example, any one or more additional or alternative features, including but not limited to one or more of interlock protrusions, fastening elements, cover plates, stem extensions, stem retaining nuts, and valve stems, may be combined in an integrated design through additive manufacturing to integrate components and / or minimize assembly.

[0113] The spring return cartridge elements 211, 311, 411 can include structural features and configurations configured to facilitate manufacturing using additive manufacturing techniques. For example, a draft angle (e.g., a 45° surface) may be provided on the transition surface between the shaft bearing portion and the upper wall portion and the offset portion to enable printing without support material. As another example, a spiral or clock-type torsion spring configuration may be selected to facilitate printability compared to a helical spring configuration. In other embodiments, different spring loading configurations, including, for example, a helical torsion spring configuration similar to that shown in the embodiments of FIGS. 3-5, may be utilized.

[0114] Aspects of the invention have been described with reference to exemplary embodiments. Modifications and variations will occur to others upon a reading and understanding of this specification. This specification is intended to cover all such modifications and variations as fall within the scope of the appended claims or their equivalents.

Claims

1. A spring return cartridge for a rotary-actuated valve, wherein the spring return cartridge is A torsion spring having a spring load intermediate portion extending between the first end and the second end, A spring carrier having a first portion enclosed by the torsion spring and rotatably fixed to the first end of the torsion spring, and a second portion rotatably coupled to the second end of the torsion spring, wherein the second portion of the torsion spring is rotatable relative to the spring carrier and to the first end of the torsion spring between a first rotation limit position and a second rotation limit position, and the intermediate portion of the torsion spring biases the second end of the torsion spring to the first rotation limit position and maintains a spring load state at the first rotation limit position. Equipped with, A spring return cartridge wherein the first end of the torsion spring includes at least one fastener hole aligned with a corresponding fastener hole in a first portion of the spring carrier, and a fastener is installed through the aligned fastener hole to rotationally secure the first end of the torsion spring to the first portion of the spring carrier.

2. The spring return cartridge according to claim 1, wherein at least one of the first and second ends of the torsion spring is provided with an annular collar that provides one or more mounting points to the corresponding first and second portions of the spring carrier.

3. The spring return cartridge according to claim 2, wherein the ring-shaped collar of the torsion spring comprises a first end collar at the first end.

4. The spring return cartridge according to claim 3, wherein the first end collar is formed integrally with the intermediate portion of the torsion spring.

5. The spring return cartridge according to claim 2, wherein the ring-shaped collar of the torsion spring comprises a second end collar at the second end.

6. The spring return cartridge according to claim 5, wherein the second end collar is formed integrally with the intermediate portion of the torsion spring.

7. The spring return cartridge according to claim 2, wherein the ring-shaped collar provides a plurality of attachment points to corresponding first and second portions of the spring carrier.

8. The spring return cartridge according to claim 1, wherein the torsion spring is enclosed within the spring carrier.

9. The spring return cartridge according to claim 1, wherein the torsion spring comprises a helical spring.

10. The spring return cartridge according to claim 1, wherein the first portion of the spring carrier comprises the lower end of the spring carrier, and the second portion of the spring carrier comprises the upper end of the spring carrier.

11. The spring return cartridge according to claim 1, wherein the spring load intermediate portion, the first end, and the second end of the torsion spring are formed as monolithic components.

12. The spring carrier is assembled with the torsion spring, as described in claim 1, for the spring return cartridge.

13. A spring return cartridge for a rotary-actuated valve, wherein the spring return cartridge is A torsion spring having a spring load intermediate portion extending between the first end and the second end, A spring carrier having a first portion enclosed by the torsion spring and rotatably fixed to the first end of the torsion spring, and a second portion rotatably coupled to the second end of the torsion spring, wherein the second portion of the torsion spring is rotatable relative to the spring carrier and to the first end of the torsion spring between a first rotation limit position and a second rotation limit position, and the intermediate portion of the torsion spring biases the second end of the torsion spring to the first rotation limit position and maintains a spring load state at the first rotation limit position. Equipped with, A spring return cartridge wherein the second end of the torsion spring includes at least one fastener hole aligned with a corresponding slot in a second portion of the spring carrier, the fastener being placed in the fastener hole and extending through the slot, rotatably securing the second end of the torsion spring to the second portion of the spring carrier.

14. The spring return cartridge according to claim 13, wherein the first end of the torsion spring includes at least one fastener hole aligned with a corresponding fastener hole in a first portion of the spring carrier, and a fastener is installed through the aligned fastener hole to rotationally secure the first end of the torsion spring to the first portion of the spring carrier.

15. A spring return handle mechanism for assembly with a valve, wherein the spring return handle mechanism is It is a spring return cartridge, A torsion spring having a spring load intermediate portion extending between the first end and the second end, A spring carrier having a first portion that is covered and encased by the torsion spring, rotatably fixed to the first end of the torsion spring and attachable to the valve body of the valve, and a second portion that is rotatably coupled to the second end of the torsion spring, A spring return cartridge equipped with, A valve handle that can be gripped by the user, A stem fixed by a spring return cartridge, the stem including an end that can be attached to the valve handle and a stem interlock portion configured to interlock with a spring interlock portion on the second end of the torsion spring, Equipped with, The stem interlock portion comprises an annular shoulder extending radially on the stem, and the spring interlock portion comprises an annular counterbore extending radially within the second end of the torsion spring. The spring return handle mechanism further comprises a nut that is screwable to the stem end and configured to be tightened against the spring interlock portion to maintain an interlock engagement between the spring interlock portion and the stem interlock portion.

16. The spring return handle mechanism according to claim 15, wherein the shoulder and the counterbore have grooved surfaces that interlock with each other.

17. The spring return handle mechanism according to claim 15, wherein the shoulder and the counterbore are provided with knurled surfaces.

18. The spring return handle mechanism according to claim 15, wherein the stem comprises a stem extension having a lower bore configured to receive the valve stem of the valve.

19. The spring return handle mechanism according to claim 15, wherein the second end of the torsion spring includes at least one fastener hole aligned with a corresponding slot in a second portion of the spring carrier, the fastener being placed in the fastener hole and extending through the slot, rotatably securing the second end of the torsion spring to the second portion of the spring carrier.

20. The spring return handle mechanism according to claim 15, wherein the first end of the torsion spring includes an internal female thread for screwing with the male threaded portion of the valve body of the valve.

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