Poppet and Seat Cartridge Valve Subassembly

Abstract

The valve subassembly includes a body plug, a poppet, and a seat carrier. The body plug includes a tubular sidewall defining a central cavity and one or more lateral flow openings in the sidewall. The poppet includes upper and lower stem portions extending axially and a poppet seal portion extending radially between the upper and lower stem portions, the lower stem portion and the poppet seal portion being received in the central cavity of the body plug. The seat carrier is assembled with the body plug and includes a central bore through which the upper stem portion of the poppet is received, the seat carrier holding the seat seal in radial alignment with the poppet seal portion.

Description

Technical Field

[0001] Cross - References to Related Applications This application claims priority and all benefits thereof to U.S. Provisional Patent Application No. 63 / 158,408 for POPPET AND SEAT CARTRIDGE VALVE SUBASSEMBLY, filed on March 9, 2021, and U.S. Provisional Patent Application No. 63 / 180,166 for POPPET - STYLE VALVE ARRANGEMENTS, filed on April 27, 2021, and the entire disclosures of both applications are 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 Art

[0003] Poppet - style valves are known for use as flow control mechanisms for gas and liquid fluid delivery, flow rate control, and pressure control. A poppet valve arrangement includes an axially movable stem having a sealing portion (e.g., an enlarged disk, a tapered end) that seals against an annular seat within a valve passage to allow fluid flow through the valve passage when the stem is in the closed position and axially disengages from the seat when the stem is in the open position. Many different types of fluid control devices utilize poppet valve mechanisms, including, for example, diaphragm valves, bellows valves, and pressure regulators.

Summary of the Invention

[0004] According to an exemplary embodiment of the present disclosure, a valve subassembly includes a body plug, a poppet, and a seat carrier. The body plug includes a tubular sidewall defining a central cavity, and one or more lateral flow openings within the sidewall. The poppet includes an axially extending upper stem portion and a lower stem portion, and a poppet seal portion extending radially between the upper stem portion and the lower stem portion, and the lower stem portion and the poppet seal portion are received within the central cavity of the body plug. The seat carrier is assembled with the body plug and includes a central bore through which the upper stem portion of the poppet is received, and the seat carrier holds a seat seal in a radial alignment with the poppet seal portion.

[0005] According to another exemplary embodiment of the present disclosure, the pressure regulator includes a valve body housing, a valve subassembly, a loading mechanism, and a sensing element. The valve body housing includes a central bore disposed between a first end port and a second end port. The valve subassembly includes a body plug, a poppet, and a seat carrier. The body plug includes a tubular sidewall defining a central cavity and one or more lateral flow openings within the sidewall. The body plug is mounted within the central bore of the valve body such that at least one of the one or more lateral flow openings is in fluid communication with the first end port. The poppet includes an axially extending upper stem portion and a lower stem portion, and a poppet seal portion radially extending between the upper stem portion and the lower stem portion, and the lower stem portion and the poppet seal portion are received within the central cavity of the body plug. The seat carrier is assembled with the body plug and includes a central bore through which the upper stem portion of the poppet is received, and the seat carrier holds a seat seal in a radial alignment with the poppet seal portion. The loading mechanism is assembled with the valve body housing and is operable to apply a set load force to the poppet for downward movement of the poppet. The sensing element is disposed between the loading mechanism and the poppet to transmit the load force from the loading mechanism to the poppet, and when the fluid pressure within one of the first end port and the second end port exceeds a pressure setting corresponding to the set load force, the sensing element is movable relative to the set load force to allow upward movement of the poppet.

[0006] According to another exemplary embodiment of the present disclosure, a method for replacing a poppet and a seat seal within a regulator valve assembly is contemplated. In an exemplary method, a regulator valve assembly is provided, the regulator valve assembly including a valve body having a valve body housing defining a central bore, and a valve cartridge sub-assembly including a body plug and a seat carrier assembled together to hold a poppet and a seat seal therebetween, the body plug being mounted within the central bore. The valve cartridge sub-assembly is removed from the valve body by disassembling the body plug from the valve body housing, thereby extracting the body plug, seat carrier, poppet, and seat seal from the central bore. A replacement valve cartridge sub-assembly is assembled with the regulator valve body to mount a new poppet and seat seal within the valve body housing bore.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 2A

Figure 3

Figure 4

Figure 4A

Figure 5

Modes for Carrying Out the Invention

[0008] 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 the exemplary embodiments, is not limited by the exemplary embodiments, and the terms used in the claims have their full ordinary meaning. For example, the specific embodiments described herein relate to pressure reducing regulator valve arrays, and the features of this application may additionally or alternatively be applied to other types of valves, including, for example, back pressure regulator valve arrays, shut-off valves, check valves, and relief valves. The terms "poppet valve" and "poppet type valve" as used herein are intended broadly to include any valve that includes a stem carrying a seal member that is incorporated into sealing engagement with an annular seat by longitudinal movement of the stem. The terms "seal" and "sealing engagement" are intended to include, in addition to leak-free or fluid-tight seals, a condition of reduced flow resulting from contact between seal surfaces.

[0009] The various inventive aspects, concepts, and features of the invention are described and illustrated herein as being embodied in combination in exemplary embodiments, and those various aspects, concepts, and features can be used in many alternative embodiments, either individually or in any of their various combinations and sub - combinations. All such combinations and sub - combinations are intended to be within the scope of the invention unless expressly excluded herein. Still further, alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, etc., and alternatives for various alternative embodiments, forms, adaptations, and functions of the various aspects, concepts, and features of the invention can be described herein, and such description is not intended to be a complete or comprehensive 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 inventive aspects, concepts, or features into additional embodiments and uses within the scope of the invention even if such embodiments are not expressly disclosed herein. Additionally, even when some features, concepts, or aspects of the invention may be described herein as being in a preferred arrangement or method, such description is not intended to suggest that such features are required or essential unless so expressly stated. Still further, exemplary or representative values and ranges may be included to assist in the understanding of the present disclosure, but such values and ranges are not to be construed in a limiting sense and are intended to be significant values or ranges only if so expressly stated. Parameters identified as “approximately” or “about” and defined values are intended to include the defined value, values within 5% of the defined value, and values within 10% of the defined value unless otherwise expressly stated. Further, the drawings attached to this application may be of the same scale, but it is understood that this is not essential, and thus it can be understood that various ratios and proportions apparent within the drawings are taught.Moreover, various aspects, features, and concepts may be clearly identified herein as being inventive or forming part of the invention, and such identification is not intended to be exclusive. Rather, all inventive aspects, concepts, and features described herein may exist without being clearly identified as such a particular invention or as part of a particular invention. Instead, the invention is set forth in the appended claims. Unless stated otherwise, descriptions of exemplary methods or processes are not limited to including all steps as required in all cases, nor is the order in which steps are presented required or construed as mandatory.

[0010] Referring to FIG. 1, in an exemplary embodiment schematically illustrated, a poppet type valve assembly 10 includes a valve body 20 defining a valve passage 22 between an inlet port 21 and an outlet port 23, and an annular valve seat 30 extending around a central portion 24 extending axially of the valve passage. The poppet 40 is assembled with the valve body 20 and includes an axially extending poppet stem 41 and a radially extending poppet seal portion 42. The actuator 50 is assembled with the poppet stem 41 to control the axial movement of the poppet 40 between a closed position where the poppet seal portion 42 seals against the valve seat 30 (e.g., to prevent the flow rate from exceeding an acceptable leakage rate) and an open position where the poppet seal portion is axially separated from the valve seat to allow fluid flow to pass through the axially extending portion 24 of the valve passage 22. The actuator 50 may be operable by a user for selective movement of the poppet 40 (e.g., manually, pneumatically, or electrically operable). Alternatively, the actuator 50 may be configured to move automatically or allow movement of the poppet under predetermined system conditions. For example, the actuator arrangement may be configured to cause or allow automatic movement of the poppet 40 at a threshold system fluid pressure, such as to relieve angular fluid pressure from the system (in the case of a relief valve), prevent backflow (in the case of a check valve), or reduce the outlet pressure (in the case of a pressure regulator). An example of a pressure regulator having a poppet type valve arrangement is disclosed in a product catalog entitled Pressure Regulator RHPS SERIES (MS-02-430, Rev K, May 2020), which is available online to the public or otherwise from the Swagelok Company and is hereby incorporated by reference in its entirety herein.

[0011] Valve seats and poppet seal surfaces, such as those of a regulator valve, are particularly sensitive to contamination and often affected by wear, especially in high-cycle applications. According to an exemplary aspect of the present disclosure, the valve may be provided with a poppet and seat subassembly that facilitates replacement of the poppet and seat seal and protects the poppet and seat seal surfaces from user contact.

[0012] Figures 2 and 2A illustrate an exemplary pressure reducing regulator valve assembly 100 that includes a regulator valve body 110 defining a valve passage 112 between a first end (e.g., inlet) port 111 and a second end (e.g., outlet) port 113, and an annular valve seat seal 135 disposed within the valve body between the inlet port and the outlet port. The poppet 140 is assembled with the valve body 110 and includes an axially extending upper stem portion 141 and lower stem portion 143, and a poppet seal portion 142 that extends radially between the upper stem portion and the lower stem portion. The poppet 140 is axially movable between a lower open position in which the poppet seal portion is axially spaced from the seat seal 135 and an upper closed position in which the poppet seal portion is in sealing engagement with the seat seal.

[0013] According to an exemplary aspect of the present disclosure, the regulator valve assembly 100 includes a valve cartridge subassembly 101 (also shown in FIG. 3) configured to facilitate removal and replacement of the poppet 140 and the seat seal 135, for example, to replace a worn or damaged seal surface. In the illustrated embodiment, the subassembly 101 includes a body plug 120 having a tubular sidewall 121 defining a central cavity 122 that receives the seal portion 142 and the lower stem portion 143 of the poppet 140, and a seat seal retaining seat carrier 130 that is assembled with the body plug on the poppet 140 to hold the poppet and the seat seal 135 together as a replaceable cartridge subassembly.

[0014] The seat carrier 130 includes a lower end portion of the seat carrier that engages the upper counterbore 122-1 within the body plug cavity 122, a male threaded lower end portion 134 that is screwed to the female threaded upper end portion 124 of the body plug 120, and an upper stem portion 141 of a poppet 140 that extends into the central bore 131 of the seat carrier. The seat seal 135 is fixed to or held by (e.g., partitioned therein and integral with) the lower end portion 134 of the seat carrier 130 in a radial alignment with the poppet seal portion 142 for engagement with the poppet seal portion when the poppet 140 is in the closed position.

[0015] The body plug 120 is configured to be mounted within a central bore 114 within the body housing 115 so as to form the valve body 110. When the poppet 140 is in the open position, an exemplary body plug 120 includes one or more lateral openings 123 within a side wall 121 positioned to align with the valve body inlet port 111 to allow fluid flow from the inlet port into the body plug cavity 122 and fluid flow to the outlet port between the poppet seal portion 142 and the valve seat seal 135. An exemplary seat carrier 130 includes one or more lateral openings 133 positioned to align with the valve body outlet port 113. The openings 123, 133 can be peripherally spaced around each of the body plug 120 and the seat carrier 130 to ensure at least partial alignment of at least one of the openings 123, 133 with at least a portion of the inlet port 111 and the outlet port 113 regardless of the rotational position of the body plug 120 and the seat carrier 130 within the valve body housing 115. Additionally, the body plug 120 can be provided with an annular recess 123-1 that intersects the body plug opening 123 to provide a fluid flow path, for example, between the body plug opening and the inlet port 111 regardless of any misalignment of either of the body plug openings with the inlet port. The seat carrier bore 131 can be provided with a tapered inner surface 131-1 to promote, for example, the expansion of a gas flowing through the seat carrier.

[0016] The O-ring / gasket seal 127 (and a backup ring, not shown) is provided in the groove 126 within the body plug 120 so as to provide a leak-free body seal between the inlet port 111 and the lower end of the central bore 114 and between the inlet port and the outlet port 113. One or more O-ring / gasket seals 137 (and a backup ring, not shown) may be provided in the groove 136 within the seat carrier 130 so as to provide a leak-free seal between the outlet port 113 and the load mechanism 150 (described in more detail below).

[0017] For secure mounting of the body plug 120 within the body housing 115, many different arrangements may be provided. For example, the male threaded portion 128 of the body plug 120 may be threaded into the female threaded portion 118 of the central bore 114. As shown in the exploded perspective view of FIG. 2A, the end portion of the body plug 120 may be provided with a flat surface 120-1 for engagement and tightening by a tool (e.g., a torque wrench). Additionally or alternatively, the end portion of the body plug 120 may be provided with other tool engagement features, such as a hole 120-2 for engagement with a spanner wrench.

[0018] Thus, in an exemplary method of replacing the poppet 140 and the seat seal 135 within the regulator valve assembly 100 (e.g., replacing worn / damaged seal surfaces), the valve cartridge sub-assembly 101, which includes the body plug 120 and the seat carrier 130 assembled together so as to hold the poppet 140 and the seat seal 135 therebetween, is removed from the regulator valve body 110 by disassembling the body plug from the regulator valve body housing 115 (e.g., unscrewing), thereby pulling the body plug, seat carrier, poppet, and seat seal out of the central bore 114 of the regulator valve body housing. A replacement valve cartridge sub-assembly, which may be substantially identical (but not necessarily) to the removed valve cartridge sub-assembly, is then assembled with the regulator valve body so as to seat new poppet 140 and seat seal 135 within the regulator valve body bore 114.

[0019] In other embodiments, the valve cartridge subassembly may include a body plug secured to the valve body by a bolting arrangement, such as to reduce the mounting torque required during assembly / reassembly. FIGS. 4 and 4A illustrate an exemplary pressure reducing regulator valve assembly 200, which includes a regulator valve body 210 defining a valve passage 212 between a first end (e.g., inlet) port 211 and a second end (e.g., outlet) port 213, and an annular valve seat seal 235 disposed within the valve body between the inlet port and the outlet port. The poppet 240 is assembled with the valve body 210 and includes an axially extending upper stem portion 241 and a lower stem portion 243, and a seal portion 242 extending radially between the upper stem portion and the lower stem portion. The poppet 240 is axially movable between a lower open position where the poppet seal portion is axially spaced from the seat seal 235 and an upper closed position where the poppet seal portion is in sealing engagement with the seat seal.

[0020] The regulator valve assembly 200 includes a valve cartridge subassembly 201 (also shown in FIG. 5) configured to facilitate removal and replacement of the poppet 240 and the seat seal 235, such as to replace worn or damaged seal surfaces. In the illustrated embodiment, the subassembly 201 includes a body plug 220 having a tubular side wall 221 defining a central cavity 222 that receives the seal portion 242 and the lower stem portion 243 of the poppet 240, and a seat seal that holds a seat carrier 230 assembled with the body plug on the poppet 240 to hold the poppet and the seat seal 235 together as a replaceable cartridge subassembly 201.

[0021] The seat carrier 230 includes a male screw lower end portion 234 screwed to the female screw upper end portion 224 of the body plug 220. In the illustrated embodiment, the seat carrier 230 is provided with an extension or ground 232 that is mounted with respect to the lower end portion of the seat carrier and engages a first upper counterbore 222-1 within the body plug cavity 222. By providing the seat carrier as a two-component configuration, the surface features of the seat carrier (e.g., the tapered inner surface 231-1 described below) can be more easily manufactured. The upper stem portion 241 of the poppet 240 extends into the central bore 231 of the seat carrier 230. The seat seal can be partitioned from the seat carrier or seat carrier ground, and in the illustrated embodiment, the seat seal 235 is provided as a separate seal ring fixed between the seat carrier ground 232 and a second upper counterbore 222-4 within the body plug cavity for engagement with the poppet seal portion when the poppet 240 is in the closed position. As shown, the seat seal 235 can be provided with grooves for holding a gasket / O-ring seal for sealing engagement with the seat carrier ground 232 and the second upper counterbore 222-4.

[0022] Many different types of seal rings can be used and, in the illustrated embodiments, the seal ring 235 is fixed to or held on a harder (e.g., having a hardness greater than about 80 HRB) inner circumferential rib, flange, rail, or other such protrusion protruding into the central portion of the valve passage, or is provided as an outer-coated, overcoated, or otherwise joined annular softer material (e.g., having a hardness of less than about 100 HRM). The stiffened underlying protrusions allow for the use of a relatively thin (e.g., about 0.05 inches to about 0.10 inches) seal ring, thereby minimizing the thermal expansion, material flow, and deformation of the softer material seal ring and providing a rigid support for use in higher (e.g., up to about 6000 psi) applications. Any suitable material can be used to provide adequate seal performance within the valve. For example, the seal ring can be provided in a suitable plastic (e.g., PEEK), and the seal ring holding the protrusions can be provided in 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). An exemplary sheet seal ring having a joined seal portion is described in U.S. Provisional Patent Application No. 63 / 180,166, filed May 26, 2021, entitled POPPET-STYLE VALVE ARRANGEMENTS, the entire disclosure of which is incorporated herein by reference.

[0023] The body plug 220 is configured to be mounted within the central bore 214 in the body housing 215 so as to form the valve body 210. When the poppet 240 is in the open position, an exemplary body plug 220 includes one or more lateral openings 223 in the side wall 221 positioned to align with the valve body inlet port 211 so as to allow fluid flow from the inlet port 211 into the body plug cavity 222 and fluid flow to the outlet port 213 between the poppet seal portion 242 and the valve seat seal 235. An exemplary seat carrier 230 includes one or more lateral openings 233 positioned to align with the valve body outlet port 213. The openings 223, 233 can be peripherally spaced around each of the body plug 220 and the seat carrier 230 so as to ensure at least partial alignment of at least one of the inlet port 211 and the outlet port 213 with at least one of the openings 223, 233, regardless of the rotational position of the body plug 220 and the seat carrier 230 within the valve body housing 215. Additionally, the body plug 220 can be provided with an annular recess 223-1 intersecting the body plug opening 223 so as to provide a fluid flow path, for example, between the body plug opening and the inlet port 211, regardless of any misalignment of either the body plug opening with the inlet port.

[0024] O-ring / gasket seals (e.g., gasket and backup ring) 227 are provided in the groove 226 within the body plug 220 so as to provide a leak-free body seal between the inlet port and the lower end of the central bore 214 and between the inlet port 211 and the outlet port 213. One or more O-ring / gasket seals (e.g., having a backup ring) 237 can be provided in the groove 236 within the seat carrier 230 so as to provide a leak-free seal between the outlet port 213 and the load mechanism 250 (described in more detail below).

[0025] For the safe mounting of the body plug 220 within the body housing 215, many different arrangements can be provided. In the illustrated embodiment, when the tubular sidewall 221 is axially inserted into the body housing bore 214, the mounting plate 225 is fixed to the lower end of the body plug 220, for example, by mounting bolts 205, so as to fix the body plug to the body housing 215. In other embodiments, the mounting plate can be integrally formed with the body plug, can be welded to the body plug, or otherwise can be attached to the body plug. As shown in FIG. 4A, when inserted within the body housing bore 214, the mounting plate 225 includes a ring of mounting holes 225-1 that align with body housing mounting holes 215-1 to receive mounting bolts 207 for fixing the body plug 220 to the valve body housing 215. The mounting holes 225-1 can be equally spaced around the mounting plate 225 to allow connection of the mounting plate to the valve body housing 215 in a plurality of orientations. Alternatively, the mounting plate and the body housing mounting holes 225-1, 215-1 can be arranged to ensure attachment in a single orientation.

[0026] In an exemplary method of replacing the poppet 240 and seat seal 235 within the regulator valve assembly 200 (e.g., replacing worn / damaged seal surfaces), the valve cartridge sub-assembly 201, which includes a body plug 220 and a seat carrier 230 assembled together to hold the poppet 240 and seat seal 235 therebetween, is removed from the regulator valve body 210 by removing the mounting bolts 207 from the mounting plate and the body housing mounting holes 225-1, 215-1 and pulling the body plug, seat carrier, poppet, and seat seal out of the central bore 214 of the regulator valve body housing 215. A replacement valve cartridge sub-assembly 201, which may be substantially identical (but not necessarily) to the removed valve cartridge sub-assembly, is then assembled with the regulator valve body housing 215 by axially inserting the tubular end portion 221 of the body plug 220 into the body housing bore 214. As shown, the upper or tip portions of the seat carrier 230 and the body plug 220 may be provided with tapered or chamfered surfaces 230-1, 230-2, 221-1 to facilitate alignment and insertion of the seat carrier and the body plug, for example. The body plug 220 is then secured by mounting bolts 207 mounted through the aligned mounting holes 225-1, 215-1 within the mounting plate 225 and the body housing 215 to secure the new poppet 240 and seat seal 235 within the regulator valve body bore 214.

[0027] The regulator valve assembly may include a sensing element (e.g., diaphragm, piston), and for the sensing element, a fluid pressure (e.g., compressed fluid in the outlet port of a pressure reducing regulator) may act against a load force applied by a load mechanism (e.g., biasing spring, compressed "dome" chamber) to move the sensing mechanism when the fluid pressure exceeds a pressure setting for movement of the poppet. The poppet and the poppet within the seat cartridge subassembly may extend beyond the seat carrier for engagement with the outer sensing element, and in the illustrated embodiments, the piston sensing elements 180, 280 are assembled with the central bores 131, 231 of the seat carriers 130, 230 partitioned above the upper stem portions 141, 241 of the poppets 140, 240. One or more O-ring / gasket seals (e.g., having backup rings) 187, 287 may be provided in the grooves 186, 286 within the pistons 180, 280 to seal by the seat carrier bores 131, 231 to provide a leak-free seal between the outlet ports 113, 213 and the load mechanisms 150, 250. The pistons 180, 280 may be provided with shoulder portions 188, 288 that engage counterbores 138, 238 within the seat carriers 130, 230 to hold the pistons 180, 280 by the valve cartridge subassemblies 101, 201.

[0028] A downward force is applied to the poppets 140, 240 through the pistons 180, 280 so as to bias the poppets toward the open position by the load mechanism (e.g., the shown fluid-compressed chamber or dome load mechanisms 150, 250). The outlet ports 113, 213 are in fluid communication with the pistons 180, 280, and as a result, the compressed fluid in the outlet ports applies an upward force to the pistons. In such an arrangement, when the outlet port pressure exceeds the set pressure, the upward fluid pressure on the pistons 180, 280 exceeds the downward load mechanism force, moving the pistons upward, thereby enabling the poppets 140, 240 to move to the closed position.

[0029] As shown, poppets 140, 240 may be provided with inner passages 145, 245 (in grooves 146, 246) that extend from the lower stem portions 143, 243 of the poppets to the upper portions downstream of the seat seals 135, 235 (i.e., above them) together with gasket seals 147, 247 that provide a seal between the lower stem portions of the poppets and the narrower base material portions 122-2, 222-2 of the body plug cavities 122, 222. As a result, when the poppets 140, 240 are in the closed position, the inlet or upstream fluid pressure on the poppet is offset by the outlet or downstream fluid pressure. This arrangement may be referred to as a balanced poppet design, and a balanced poppet design can result in reducing the seat load, for example, to reduce seat wear / deformation. In such an arrangement, poppet springs 148, 248 may be provided within the body plug cavities 122, 222 and compressed between the lower counterbores 122-3, 222-3 and the poppets 140, 240 (e.g., at shoulders 144, 244) to provide a consistent closing / sealing force on the poppets independent of the system fluid pressure.

[0030] To assemble the exemplary valve subassembly 101 of FIGS. 2, 2A, and 3, poppet 140 and poppet spring 148 are inserted into the central cavity 122 of body plug 120 together with the lower stem portion 143 of the poppet received within the narrower base material portion 122-2 of body plug cavity 122, and the poppet spring engages the lower counterbore 122-3 of the body plug cavity. Piston 180 is mounted from the bottom end through the central bore 131 of seat carrier 130, and the lower shoulder portion 188 of the piston engages counterbore 138 within the seat carrier. Seat carrier 130 is assembled to be threadable with body plug 120 by the partitioned seat seal 135, and the lower end portion 134 of the seat carrier engages the upper counterbore 122-1 within body plug cavity 122.

[0031] To assemble the exemplary valve subassembly 201 of FIGS. 4, 4A, and 5, the poppet 240 and the poppet spring 248 (secured to the poppet 240 using the retaining ring 249) are inserted into the central cavity 222 of the body plug 220 along with the lower stem portion 243 of the poppet received within the narrower substrate portion 222-2 of the body plug cavity 222, and the poppet spring engages the lower counterbore 222-3 of the body plug cavity. The piston 280 is mounted from the bottom through the central bore 231 of the seat carrier 230, and the lower shoulder portion 288 of the piston engages the counterbore 238 within the seat carrier. The seat seal assembly 235 and the seat carrier ground 232 are inserted within the body plug counterbores 222-4, 222-1, and the seat carrier 230 is assembled threadably to the body plug 220 such that the seat seal assembly is sealed and secured between the seat carrier extension and the second upper body plug counterbore 222-4.

[0032] To apply a selected downstream biasing force to the sensing element, many different types of loading mechanisms can be utilized. In the illustrated embodiments, the piston sensing dome load arrays 150, 250 include upper and lower dome housing shell members 151-1, 251-1, 151-2, 251-2 (fixed together, e.g., by bolts 102, 202) assembled with the valve body housing 115, 215 (e.g., by mounting screws 103, 203) that define dome chambers 152, 252, and dome load diaphragms 159, 259 having outer peripheral surfaces captured between the upper and lower shell members, and diaphragm screws 154, 254 are mounted within the dome load diaphragms through central openings and positioned to engage the upper end portions 186, 286 of pistons 180, 280. In the illustrated embodiments, support plates 155-1, 255-1, 155-2, 255-2 fix the dome load diaphragms 159, 259 to the diaphragm screws 154, 254 above and below with nuts 156, 256 to provide additional support to the diaphragms. The upper dome housing shell members 151-1, 251-1 include compression ports 153, 254 (defined, e.g., by welded end caps 151-3, 251-3) for supplying compressed fluid at a set pressure (e.g., from a secondary pressure regulator) to the dome chambers 152, 252 to apply a corresponding loading force to the dome load diaphragms 159, 259 and move the diaphragm screws 154, 254 relative to the pistons 180, 280. In another exemplary embodiment, the actuator array can include a compressed spring that applies (directly or indirectly) a downstream biasing force to the diaphragm. In one such embodiment, the compression of the spring can be adjustable to increase or decrease the downstream biasing force exerted by the spring. For example, the spring guide that engages the upper end of the spring can be lowered or raised (e.g., by a rotatable knob or handle) to increase or decrease the compression of the spring. Exemplary compressed dome and spring load arrays are described in the RHPS SERIES catalog of pressure regulators incorporated above.As described in the incorporated pressure regulator RHPS SERIES catalog above, other types of sensing mechanisms may be used instead of the exemplary pistons, such as diaphragm elements or piston elements, for example, outside the valve subassembly.

[0033] Inventive aspects have been described with reference to exemplary embodiments. Upon reading and understanding this specification, modifications and adaptations will be made. It is intended to include all such modifications and adaptations heretofore made so long as they fall within the scope of the appended claims or the scope of equivalents thereof.

Claims

1. A valve subassembly, comprising: A body plug defining a central cavity and including one or more lateral flow openings within said sidewall; A poppet including an axially extending upper stem portion and a lower stem portion, and a radially extending poppet seal portion between said upper stem portion and said lower stem portion, said lower stem portion and said poppet seal portion being received within the central cavity of said body plug; A seat carrier including a central bore through which said upper stem portion of said poppet is received, said seat carrier holding a seat seal in a radial alignment with said poppet seal portion; A piston assembled with said central bore of said seat carrier and including a lower end portion engaging said upper stem portion of said poppet and an upper end portion extending over said seat carrier; The valve subassembly further comprising: The seat carrier being assembled with said body plug to hold said poppet, said seat seal, and said piston together with said seat carrier and said body plug as a replaceable cartridge subassembly.

2. The valve subassembly according to claim 1, wherein said seat carrier is threadably assembled with said body plug.

3. The valve subassembly according to claim 1, wherein said seat carrier includes one or more lateral flow openings.

4. The valve subassembly according to claim 1, wherein said seat seal is partitioned within a lower end portion of said seat carrier.

5. The valve subassembly according to claim 1, further comprising a poppet spring disposed within the central cavity of said body plug, said poppet spring applying an upward biasing force to said poppet toward a sealing engagement with said seat seal.

6. The valve subassembly according to claim 1, wherein said piston includes a shoulder portion engaging a counterbore within the central bore of said seat carrier to hold said seat carrier and said piston together.

7. A valve, comprising: A valve body housing including a central bore disposed between a first end port and a second end port; The valve subassembly according to claim 1, wherein the body plug is mounted within a central bore of the valve body such that at least one of the one or more lateral flow openings is in fluid communication with the first end port, a valve subassembly; A valve comprising the same.

8. The valve according to claim 7, wherein the body plug is threadably assembled with a central bore of the valve body housing.

9. The valve according to claim 7, wherein the body plug includes an end flange fastened to the valve body housing.

10. A pressure regulator, A valve body housing including a central bore disposed between a first end port and a second end port; The valve subassembly according to claim 1; A load mechanism assembled with the valve body housing and operable to apply a set load force to the poppet for downward movement of the poppet; A pressure regulator comprising the same; The piston of the valve subassembly functions as a sensing element disposed between the load mechanism and the poppet to transmit the load force from the load mechanism to the poppet, and when the fluid pressure in one of the first end port and the second end port exceeds a pressure setting corresponding to the set load force, the sensing element is movable relative to the set load force to allow upward movement of the poppet, a pressure regulator.

11. The pressure regulator according to claim 10, wherein the seat carrier is threadably assembled with the body plug.

12. The pressure regulator according to claim 10, wherein the seat carrier includes one or more lateral flow openings.

13. The pressure regulator according to claim 10, wherein the seat seal is partitioned within a lower end portion of the seat carrier.

14. The pressure regulator further comprises a poppet spring disposed within a central cavity of the body plug, and the poppet spring applies an upward biasing force to the poppet toward sealing engagement with the seat seal, the pressure regulator according to claim 10.

15. The pressure regulator according to claim 10, wherein the piston includes a shoulder portion engaging a counterbore within a central bore of the seat carrier to hold the seat carrier and the piston.

16. The pressure regulator according to claim 10, wherein the body plug is assembled to be screwable into the central bore of the valve body housing.

17. The pressure regulator according to claim 10, wherein the body plug includes an end flange fastened to the valve body housing.

18. A method of replacing a poppet and a seat seal within a regulator valve assembly, the method comprising: providing a regulator valve assembly including a valve body having a valve body housing defining a central bore, and a valve sub-assembly according to claim 1, wherein the body plug of the valve sub-assembly is mounted within the central bore; removing the valve sub-assembly from the valve body by disassembling the body plug from the valve body housing, thereby withdrawing the body plug, the seat carrier, the poppet, the piston, and the seat seal from the central bore; assembling the regulator valve body and a replacement valve sub-assembly such that new poppet, piston, and seat seal are mounted within the valve body housing bore; A method comprising the above.

19. The method according to claim 18, wherein the body plug includes an external male thread portion, the central bore includes a female thread portion, and disassembling the body plug from the valve body housing comprises unscrewing the body plug from the central bore.

20. The method according to claim 18, wherein the body plug includes a mounting plate extending from an end portion of the body plug, and disassembling the body plug from the valve body housing comprises removing mounting bolts that secure the mounting plate to the valve body housing.

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