proportional solenoid valve

Abstract

To provide a proportional control valve that is not susceptible to fluctuations in pressure.SOLUTION: A solenoid assembly 86 is coupled to a valve assembly 24 to actuate the valve assembly 24. The solenoid assembly 86 includes a movable armature 102 engaged with a poppet 28 of the valve assembly 24. A plate spring 140 having a spring force is positioned between the valve assembly 24 and the solenoid assembly 86. The plate spring 140 is configured to bias a valve member 60 of the poppet 28 to engage the valve member 60 with a valve seat 30. Based on the spring force of the plate spring 140 and the voltage or current applied to the solenoid coil 134, the solenoid assembly 86 is configured to control a distance that the valve member 60 moves relative to the valve seat 30 to proportionally control an amount of flow that is permitted through the valve assembly 24.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to proportional solenoid valves. [Background technology]

[0002] This section provides background information related to the present disclosure, but is not necessarily prior art.

[0003] Valves using proportional control provide enhanced control over the amount of fluid that can pass through the valve. This can be particularly important in applications where a specific amount of gas, such as oxygen, is being provided to a patient before, during, or after a medical procedure. In this regard, if the correct amount of gas is not provided to the patient, the patient may be adversely affected. Other applications that may require proportional control include providing a precise amount of carbonation to beverages, providing fluid pressure control to mobility assistance units, and applications requiring fluid dispensing.

[0004] Previous proportional control valves have used expensive components, such as stepper motors, to actuate the valve. Additionally, previous valves have been susceptible to pressure fluctuations that affect the amount of fluid that can be allowed through the valve. Therefore, there is a need for a valve that is less expensive, has enhanced control over the amount of fluid that can pass through the valve, and includes a design that is less susceptible to pressure fluctuations that can affect the amount of flow through the valve. Summary of the Invention

[0005] This section provides a general summary of the disclosure and is not an exhaustive disclosure of its entire scope or all of its features.

[0006] According to a first aspect of the present disclosure, a valve is provided that includes a block having a cavity positioned between a fluid inlet and a fluid outlet. A valve assembly is positioned within the cavity to selectively allow communication between the fluid inlet and the fluid outlet. The valve assembly includes a hollow valve receiver having a first port in communication with the fluid inlet, a second port in communication with the fluid outlet, and a valve seat between the first and second ports. The hollow valve receiver houses a movable poppet that includes a valve member configured to engage and disengage with the valve seat to allow fluid to move from the fluid inlet through the first port to the second port and then to the fluid outlet. An electromagnetic assembly is coupled to the valve assembly that is configured to operate the valve assembly to allow communication between the fluid inlet and the fluid outlet. The electromagnetic assembly includes a movable armature engaged with the poppet, a first bushing surrounding the armature, a leaf spring positioned between the armature and the first bushing, and an electromagnetic coil configured to move the armature and the poppet to allow communication between the fluid inlet and the fluid outlet. The leaf spring is configured to bias the valve member of the poppet into engagement with a valve seat of the valve receiver. The leaf spring has a predictable spring force. The electromagnetic coil is configured to move the armature and the poppet based on a voltage or current applied to the electromagnetic coil, and the electromagnetic assembly is configured to control the distance the valve member moves relative to the valve seat of the valve receiver based on the spring force of the leaf spring and the voltage or current applied to the electromagnetic coil, thereby proportionally controlling the amount of flow allowed through the valve assembly.

[0007] In the valve according to the first aspect, the valve assembly may further include an adjustable valve seat connected to the valve receiver, positioned about the poppet, and including a terminal end engageable with the valve member when the valve member is moved away from the valve seat of the valve receiver.

[0008] In the valve according to the first aspect, the adjustable valve seat is threadably connected to the valve receiver, and the position of the adjustable valve seat is variable by adjusting the amount of threaded engagement between the adjustable valve seat and the valve receiver.

[0009] In the valve according to the first aspect, the electromagnetic assembly may include a post piece having an adjustable position within the electromagnetic assembly, and in combination with adjusting the position of the adjustable valve seat, the valve assembly may be configured to provide different flow capacities between the fluid inlet and the fluid outlet.

[0010] In the valve according to the first aspect, the electromagnetic assembly may further include a second bushing that houses a post piece, the post piece being located in proximity to the armature and configured to be magnetized by the coil to attract the armature to open the valve assembly.

[0011] In the valve according to the first aspect, the leaf spring includes an annular body having a central opening configured to receive the armature and a plurality of auxiliary openings located radially outward from the central opening.

[0012] In the valve according to the first aspect, the first bushing may include a stepped recess configured to receive a leaf spring, the stepped recess including a first annular surface and a second annular surface located radially inward from the first annular surface, and the leaf spring may be attached to the first annular surface.

[0013] In the valve according to the first aspect, the valve may further include an adapter bushing configured to connect the electromagnetic assembly to the valve assembly.

[0014] In the valve according to the first aspect, the valve assembly may further include a first partition located adjacent to a first end of the valve retainer and a second partition located adjacent to an opposing second end of the valve retainer and the armature, and the first and second partitions may be configured to balance the fluid pressures exerted at the fluid inlet and the fluid outlet so that fluctuations in fluid pressure exerted at the fluid inlet and the fluid outlet do not affect the performance of the valve assembly.

[0015] In the valve according to the first aspect, each of the first and second partitions may be formed from an annular plate, the annular plate including an annular bead surrounding a central opening of the annular plate, the bead being defined by a first annular inclined surface and a second annular inclined surface.

[0016] In the valve according to the first aspect, the valve assembly may further include a first end cap mated with a first end of the valve receiver and a second end cap mated with an opposite second end of the valve receiver, with a first septum sandwiched between the first end cap and the first end of the valve receiver and a second septum sandwiched between the second end cap and the second end of the valve receiver.

[0017] In the valve according to the first aspect, the valve assembly may include a plurality of sealing members between the poppet and the valve seat, and the plurality of sealing members may be configured to balance the fluid pressures exerted at the fluid inlet and the fluid outlet so that fluctuations in fluid pressures exerted at the fluid inlet and the fluid outlet do not affect the performance of the valve assembly.

[0018] According to a second aspect of the present disclosure, there is provided a valve including a block having a cavity positioned between a fluid inlet and a fluid outlet. A valve assembly is positioned within the cavity to selectively allow communication between the fluid inlet and the fluid outlet. The valve assembly includes a hollow valve receiver having a first end and an opposing second end, a first port in communication with the fluid inlet, a second port in communication with the fluid outlet, and a valve seat between the first and second ports; a movable poppet positioned within the valve receiver, the poppet including a valve member configured to engage and disengage with the valve seat to allow fluid to pass from the fluid inlet through the first port to the second port and then to the fluid outlet; and an adjustable valve seat coupled to the valve receiver and positioned around the poppet. an adjustable valve seat having an adjustable valve member and including a terminal end engageable with the valve member when the valve member is moved away from the valve seat of the valve receiver, a first partition located proximate a first end of the valve receiver, a second partition located proximate an opposing second end of the valve receiver, a first end cap mated with the first end of the valve receiver, and a second end cap mated with the opposing second end of the valve receiver, wherein the first partition is sandwiched between the first end cap and the first end of the valve receiver and the second partition is sandwiched between the second end cap and the second end of the valve receiver. An electromagnetic assembly is coupled to the valve assembly and configured to operate the valve assembly to allow communication between the fluid inlet and the fluid outlet. The electromagnetic assembly includes a movable armature engaged with the poppet, a first bushing surrounding the armature, a leaf spring positioned between the armature and the first bushing, and an electromagnetic coil configured to move the armature and the poppet to allow communication between the fluid inlet and the fluid outlet. The leaf spring is configured to urge the valve member of the poppet into engagement with the valve seat of the valve receiver and has a spring force, the electromagnetic coil is configured to move the armature and the poppet based on a voltage or current applied to the electromagnetic coil, and the electromagnetic assembly is configured to control the distance the valve member moves relative to the valve seat of the valve receiver based on the spring force of the leaf spring and the voltage or current applied to the electromagnetic coil to proportionally control the amount of flow allowed through the valve assembly.

[0019] In the valve according to the second aspect, the adjustable valve seat may be threadably connected to the valve receiver, and the position of the adjustable valve seat may be varied by adjusting the amount of threaded engagement between the adjustable valve seat and the valve receiver.

[0020] In the valve according to the second aspect, the electromagnetic assembly may include a post piece having an adjustable position within the electromagnetic assembly, and in combination with adjusting the position of the adjustable valve seat, the valve assembly may be configured to provide different flow capacities between the fluid inlet and the fluid outlet.

[0021] In the valve according to the second aspect, the electromagnetic assembly may further include a second bushing that houses a post piece, the post piece being located in proximity to the armature and configured to be magnetized by the coil to attract the armature to open the valve assembly.

[0022] In the valve according to the second aspect, the leaf spring includes an annular body having a central opening configured to receive the armature and a plurality of auxiliary openings located radially outward from the central opening.

[0023] In the valve according to the second aspect, the first bushing includes a stepped recess configured to receive a leaf spring, the stepped recess including a first annular surface and a second annular surface located radially inward from the first annular surface, and the leaf spring is attached to the first annular surface.

[0024] In the valve according to the second aspect, the valve may include an adapter bushing configured to connect the electromagnetic assembly to the valve assembly.

[0025] In the valve according to the second aspect, each of the first and second partitions is formed from an annular plate, the annular plate including an annular bead surrounding a central opening in the annular plate, the bead being defined by a first annular inclined surface and a second annular inclined surface.

[0026] In the valve according to the second aspect, the first and second partitions are configured to balance the fluid pressures exerted at the fluid inlet and fluid outlet so that fluctuations in the fluid pressures exerted at the fluid inlet and fluid outlet do not affect the performance of the valve assembly.

[0027] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. [Brief explanation of the drawings]

[0028] The drawings described herein are for illustrative purposes only of selected embodiments and are not intended to represent all possible implementations and are not intended to limit the scope of the present disclosure.

[0029] [Figure 1] 1 is a perspective view of a valve according to a first embodiment of the present disclosure; FIG. [Figure 2] 1 is a perspective view of a valve according to a first embodiment of the present disclosure; FIG. [Figure 3] 1 is a perspective view of a valve according to a first embodiment of the present disclosure; FIG. [Figure 4] FIG. 4 is an exploded perspective view of the valve illustrated in FIGS. 1 to 3. [Figure 5] FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 3. [Figure 6] FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 3. [Figure 7] FIG. 2 is a perspective view of a valve according to a second embodiment of the present disclosure. [Figure 8] FIG. 2 is a perspective view of a valve according to a second embodiment of the present disclosure. [Figure 9] FIG. 2 is a perspective view of a valve according to a second embodiment of the present disclosure. [Figure 10] FIG. 10 is an exploded perspective view of the valve illustrated in FIGS. 7 to 9. [Figure 11] FIG. 11 is a cross-sectional view taken along line 11-11 of FIG. 9. [Figure 12] FIG. 12 is a cross-sectional view taken along line 12-12 of FIG. 9.

[0030] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION OF THE INVENTION

[0031] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0032] It should be understood at the outset that exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that exemplary embodiments may be embodied in many different forms, and that neither should be construed as limiting the scope of the present disclosure. In some exemplary embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

[0033] Furthermore, when an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, the element or layer may be directly on, engaged with, connected to, or coupled to the other element or layer, or there may be intervening elements or layers. In contrast, when an element is referred to as being "directly on," "directly engaged with," "directly connected to," or "directly coupled to" another element or layer, there may not be intervening elements or layers. Other terms used to describe relationships between elements should be construed in a similar manner (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0034] Furthermore, terms such as first, second, and third may be used herein to describe various elements, components, regions, layers, and / or sections, but these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as "first," "second," and other number terms, when used herein, do not imply any order or sequence unless clearly indicated by context. Thus, a first element, component, region, layer, or section discussed below could be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0035] Additionally, spatially relative terms such as "in," "out," "beneath," "below," "below," "below," "above," and the like may be used herein for convenience of description to describe the relationship of one element or feature to other elements or features, as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures were inverted, elements described as being "beneath" or "beneath" other elements or features would be oriented "above" the other elements or features. Thus, the exemplary term "beneath" can encompass both an orientation of "above" and "below." A device may be otherwise oriented (rotated 90 degrees or at another orientation), and the spatially relative descriptions used herein may be interpreted accordingly.

[0036] 1-6 illustrate a proportional solenoid valve device 10 according to a first embodiment of the present disclosure. The valve device 10 is configured to proportionally control the flow of fluids, including liquids and gases. The valve device 10 includes a housing or ported cavity block 12. The cavity block 12 is generally a cubic or rectangular cubic structure having a plurality of faces 14a, 14b, 14c, 14d, 14e, and 14f. Face 14a includes a threaded inlet port 16, and the opposing face 14b includes a threaded outlet port 18. As best shown in FIG. 5, the inlet port 16 is not axially aligned with the outlet port 18. Face 14f includes a hole 20 that leads to an internal cavity 22 formed within the cavity block 12. The cavity 22 communicates with each of the inlet and outlet ports 16 and 18. Face 14e includes an elongated recess 23 having a central vent port 25. The recess 23 may be used to mount the cavity block 12 in a system in which the valve apparatus 10 is used.

[0037] Although the inlet port 16 is illustrated as being formed on the surface 14a opposite the surface 14b containing the outlet port 18, it should be understood that the inlet port 16 and outlet port 18 can be formed on adjacent surfaces of the cavity block 12 if desired. Furthermore, while the inlet port 16 and outlet port 18 are described as being threaded, and being threaded allows the cavity block 12 to be fitted with an adapter or some other type of device that provides and / or receives fluid flow, it should be understood that other attachment methods are contemplated. It should also be understood that the inlet port 16 and outlet port 18 may have their functions reversed (i.e., the inlet port 16 may function as an outlet port and the outlet port 18 may function as an inlet port). In either configuration, the valve device 10 will function in the same manner. Preferably, the cavity block 12 is formed from a rigid material, such as a metal (e.g., brass, steel, aluminum, etc.), but may be formed from other materials (e.g., polymeric materials) depending on the application for which the valve assembly 10 is intended.

[0038] As best shown in FIGS. 3-6 , the valve apparatus 10 includes a valve assembly 24 positioned within the cavity 22. The valve assembly 24 includes a valve receiver 26, a poppet 28, and an adjustable valve seat 30. The valve receiver 26 is preferably formed from a rigid material, such as a metal or polymeric material, and is a generally cylindrical, hollow structure including a first end 32 that is closed and configured to be positioned adjacent an end wall 34 of the cavity 22, and an opposite, second end 36 that is open and configured to be positioned adjacent the bore 20 of the cavity 22. The first end 32 includes a radially inwardly extending first recess 38 that is configured to receive a first valve receiver O-ring 40. The second end 36 includes a radially inwardly extending second recess 42 that is configured to receive a second valve receiver O-ring 44. Located between the first and second radially inwardly extending recesses 38, 42 is a third radially inwardly extending recess 46 that is configured to receive a third valve receiver O-ring 48. Each of the valve receiver O-rings 40, 44, and 48 is configured to provide a fluid-tight seal between the valve receiver 26 and an interior surface 50 of the cavity 22.

[0039] The valve receiver 26 includes a first pair of openings 52 or fluid ports located between the first radially inwardly extending recess 38 and the third radially inwardly extending recess 46. A second pair of openings 54 or fluid ports is located between the second radially inwardly extending recess 42 and the third radially inwardly extending recess 46. The first opening 52 is configured to align with the inlet port 16, and the second opening 54 is configured to align with the outlet port 18. Although the first opening 52 and the second opening 54 are illustrated as being slotted, it should be understood that the first opening 52 and the second opening 54 can have any shape desired by one skilled in the art.

[0040] The poppet 28 is configured to be received within the hollow structure of the valve receiver 26 and is movable along the axis X of the valve assembly 24. The poppet 28 is preferably formed from a rigid material, such as a metal or polymeric material, and includes a proximal end 56 configured to be positioned proximate the first end 32 of the valve receiver 26 and an opposite distal end 58 configured to be positioned proximate the second end 36 of the valve receiver 26. A valve member 60 is positioned between the proximal and distal ends 56, 58. The valve member 60 is configured to abut a valve seat 62, which is part of the valve receiver 26, when the valve assembly 24 is in the closed position. As will be described in more detail below, when the valve assembly 24 is actuated, the valve member 60 is moved away from the valve seat 62, which allows fluid to flow from the inlet 16 through the first opening 52, past the valve member 60 toward the distal end 58 of the poppet 28, and through the second opening 54 into the outlet 18. Alternatively, if the outlet port 18 functions as an inlet, the flow direction could be configured such that fluid flows from the outlet port 18, through the second opening 54, past the valve member 60, through the first opening 52, and out the inlet port 16.

[0041] Poppet 28 further includes a first seal member 64 mounted in a first recess 66 formed in proximal end 56 and a second seal member 68 mounted in a second recess 70 formed in distal end 58. First seal member 64 and second seal member 68 are similar to first O-ring 40, second O-ring 44, and third O-ring 48, but are sized to accommodate poppet 28. First seal member 64 is configured to sealingly engage an inner surface 72 of valve receiving member 26 at first end 32. Second seal member 68 is configured to sealingly engage an inner surface 74 of adjustable valve seat 30.

[0042] Continuing with reference to FIGS. 3-6 , the adjustable valve seat 30 is a cylindrical member configured to receive the distal end 58 of the poppet 28. The adjustable valve seat 30 includes an externally threaded surface 76 configured to mate with an internally threaded surface 78 formed on the inner surface of the valve receiver 26 at its second end 36. As best shown in FIG. 5 , the adjustable valve seat 30 is described as “adjustable” to the extent that a terminal end 80 of the adjustable valve seat 30 can overlap the second opening 54 formed in the valve receiver 26. This may restrict flow through the second opening 54 when the valve member 60 contacts the terminal end 80. To increase or decrease flow through the second opening 54 formed in the valve receiver 26, the amount of threaded engagement between the externally threaded surface 76 of the adjustable valve seat 30 and the internally threaded surface 78 of the valve receiver 26 can be adjusted (i.e., reduced or increased) so that the terminal end 80 does not overlap the second opening 54. The adjustable valve seat 30 includes a groove 82 formed therein that is configured to receive an adjustable seat O-ring 84 that sealingly engages the inner surface 72 a of the valve receiver 26 .

[0043] The valve apparatus 10 includes an electromagnetic assembly 86 configured to actuate the valve assembly 24. The electromagnetic assembly 86 includes an adapter bushing 88 configured to connect the electromagnetic assembly 86 to the valve assembly 24. In this regard, the adapter bushing 88 includes a hollow cylindrical body 90 having a first section 92, the first section having a smaller diameter than a second section 94. As best shown in FIG. 5 , the first section 92 includes internal threads 96 configured to mate with external threads 98 formed on the valve receiver 26. Furthermore, the first section 92 includes an outer surface 100 configured to mate with the bore 20 of the hollow block 12.

[0044] An armature 102 is positioned within the electromagnetic assembly 86. The armature 102 is a solid member formed from a magnetically attractable material and includes a mating end 104 configured to mate with an internally threaded end 106 of the poppet 28. The mating end 104 includes a threaded protrusion 108 that is connected to a body 110 of the armature 102 by a radially narrowed neck 112. The internally threaded end 106 of the poppet 28 is configured to receive the threaded protrusion 108. The radially narrowed neck 112 is connected to the body 110 of the armature 102 through a radially enlarged shoulder 116. The shoulder has a larger diameter than each of the threaded protrusion 108, neck 112, and body 110. The body 110 has a larger diameter than the threaded protrusion 108 and neck 112. The armature 102 is movable and, when a voltage or current is applied to the electromagnetic assembly 86, the armature 102 is capable of moving the poppet 28 between an open position and a closed position.

[0045] Within the adapter bushing 88, a hollow lower bushing 118 guides the body 110 of the armature 102. The lower bushing 118 includes an inner surface 120 that extends along an outer surface 122 of the body 110 of the armature 102. The lower bushing 118 includes a main body 124 and a tubular sleeve 126. The main body 124 includes a threaded surface 128 that is configured to mate with a threaded surface 130 of an electromagnetic housing 132 that houses an electromagnetic coil 134. An end face 136 of the main body 124 facing the radially enlarged shoulder 116 includes a stepped annular recess 138 that is configured to clear a leaf spring 140 positioned between the shoulder 116 and the annular recess 138. The recess 138 is stepped, with a first annular surface 142 of the recess 138 located closer to the shoulder 116 than a second annular surface 144 of the recess 138. The leaf spring 140 is mounted on the first annular surface 142, with the second annular surface 144 located further away from the shoulder 116, allowing the leaf spring 140 to flex as the armature 102 is moved toward and away from the valve assembly 24.

[0046] As best shown in FIG. 4 , the leaf spring 140 includes an annular body 146 having a central opening 148 configured to receive the body 110 of the armature 102. Radially outward from the central opening 148 are a plurality of auxiliary openings 150. The auxiliary openings 150 may be circular or elliptical in shape, although any shape for the auxiliary openings 150 may be selected that allows the leaf spring 140 to flex when the armature 102 is moved. The leaf spring 140 may be formed from a rigid, yet flexible, material. Exemplary materials include metallic and polymeric materials. The leaf spring 140 is designed to position the valve assembly 24 in a closed position.

[0047] As noted above, the electromagnetic housing 132 contains an electromagnetic coil 134. The coil 134 is mounted on a hollow cylindrical support structure 152. As best shown at 4 and 6, the coil 134 includes a pair of conductors 154 that allow a current or voltage to be applied to the coil 134. Located within the hollow support structure 152 is an upper bushing 156 that includes a post piece 158 formed from a magnetizable material.

[0048] The upper bushing 156 is a sleeve-like structure that includes a cylindrical sleeve 160 that extends along the post 158 ​​and a radially outwardly extending flange 162 that is configured to be positioned between the support structure 152 and a radially inwardly extending wall 164 of the housing 132. The post 158 ​​includes a threaded surface 158 that mates with a threaded surface 160 formed in the wall 164 of the housing 132 to secure the post 158 ​​and upper bushing 156 to the housing 132. The post 158 ​​is illustrated as having an axially extending central opening 166, although this feature is not required. Attached to the housing 132 is a covering piece 168 that is designed as a plug that allows a current or voltage application device (not shown) to be connected to the conductor 154 of the coil 134.

[0049] When a current or voltage is applied to the coil 134, the post 158 ​​becomes magnetized and can magnetically attract the armature 102. When the armature 102 is pulled toward the post 158, it pulls the poppet 28 toward the post 158, causing the leaf spring 140 to flex between the radially enlarged shoulder 116 and the lower bushing 118. When the poppet 28 is pulled toward the post 158, the valve member 60 disengages from the valve seat 62 of the valve receiver 26, opening the valve assembly 24. This allows fluid to travel from the inlet 16 through the first opening 52, past the valve member 60 toward the distal end 58 of the poppet 28, and through the second opening 54 into the outlet 18. To close the valve assembly 24, the application of current or voltage to the coil 134 is terminated, at which point the leaf spring 140 is allowed to urge the armature 102 and poppet 28 away from the post 158. The valve member 60 of the poppet 28 then re-engages with the valve seat 62, closing the valve assembly 24. The same operation occurs if the functions of the valve inlet 16 and valve outlet 18 are reversed.

[0050] It should be appreciated that the combination of the position of the adjustable valve seat 30, the magnitude of the current or voltage applied to the coil 134, and the spring force exerted by the leaf spring 140 provides enhanced control over the amount of fluid that can be allowed to pass through the valve assembly 24. In other words, the combination of the position of the adjustable valve seat 30, the magnitude of the current or voltage applied to the coil 134, and the spring force exerted by the leaf spring 140 controls the distance that the valve member 60 can be moved relative to the valve seat 62, thereby increasing or decreasing the amount of fluid that can pass through the valve assembly 24.

[0051] In this regard, as noted above, the position of the adjustable valve seat 30 can be adjusted by adjusting the amount of threaded engagement between the externally threaded surface 76 of the adjustable valve seat 30 and the internally threaded surface 78 of the valve receiver 26. Furthermore, the spring force of the leaf spring 140 can be determined prior to installation within the valve apparatus 10 to control the amount of bias with which the leaf spring 140 biases the poppet valve member 60 into engagement with the valve seat 62. Once the spring force of the leaf spring 140 has been determined, the valve apparatus 10 can be tested to determine the amount of momentum of the armature 102. This testing occurs when different currents or voltages are applied to the coil 134. In this manner, the proportional amount of fluid flow through the valve assembly 24 at different currents or voltages can be determined prior to use within the system (not shown) in which the valve apparatus is being used. Furthermore, it should be understood that the spring force of the leaf spring 140 can be adjusted by changing the size and / or number of the auxiliary openings 150, by adjusting the thickness of the leaf spring 140, or through the selection of the material from which the leaf spring 140 is formed.

[0052] Regardless of how the spring force of the leaf spring 140 is determined, it should be understood that enhanced proportional control over the distance the valve member 60 is moved relative to the valve seat 62 can be improved through a combination of the selection of the leaf spring 140 and the voltage or current applied to the coil 134. Data related to the current or voltage applied to the coil 134 may be stored in a memory (not shown) of a controller (not shown) attached to the current or voltage application device (not shown).

[0053] It should also be appreciated that the valve arrangement 10 is a balanced design such that fluctuations in the fluid supply pressure will have no effect on the performance characteristics of the valve arrangement 10. In this regard, it should be appreciated that when the valve arrangement 10 is in the closed position (i.e., when the valve member 60 of the poppet 28 is in contact with the valve seat 62 of the valve receiver 26), the fluid force exerted at the inlet 16 is balanced (i.e., opposed) by the force exerted by the seal 64 of the poppet 28 on the inner surface 72 of the valve receiver 26. Similarly, when the valve arrangement 10 is in the fully open position (i.e., when the valve member 60 of the poppet 28 is in contact with the terminal end 80 of the adjustable valve seat 30), the fluid force exerted at the outlet 18 is balanced (i.e., opposed) by the force exerted by the seal 64 of the poppet 28 on the inner surface 72 of the valve receiver 26. When the valve apparatus 10 is in an intermediate open position (i.e., when the valve member 60 of the poppet 28 is disengaged from the valve seat 62 but not in contact with the terminal end 80 of the adjustable valve seat 30), the fluid forces exerted at both the inlet 16 and the outlet 18 balance (oppose) the forces exerted by the seal 64 on the inner surface 72 of the valve receiver, the forces exerted by the seal 68 on the inner surface 74 of the adjustable valve seat 30, and the forces exerted by the seal 84 on the surface 72a of the valve receiver 26. Thus, even when the fluid forces exerted at the inlet 16 and the outlet 18 vary, the fluid forces at the inlet 16 and the outlet 18 balance the forces exerted by the seals 64, 68, and 84, which enables the valve assembly 24 to provide consistent performance (e.g., fluid output at precise pressures and amounts) throughout the entire operating pressure range of the valve apparatus 10.

[0054] 7 to 12, a proportional solenoid valve arrangement 200 according to a second aspect of the present disclosure will now be described. The valve arrangement 200 is similar to the valve arrangement 10 described above. Therefore, features of the valve arrangement 200 that are common to features of the valve arrangement 10 will have the same reference numerals, and a description of the common features will be omitted.

[0055] Valve apparatus 200 includes a housing or ported cavity block 202. Cavity block 202 is substantially similar to cavity block 12, but includes a second bore 204 that communicates with bore 20, and cavity 22 extends completely through cavity block 202. Positioned within cavity 22 of cavity block 202 is a valve assembly 206. Valve assembly 206 includes valve receiver 26, poppet 28, adjustable valve seat 30, and valve receiver O-rings 40, 44, and 48. The primary difference between valve assembly 206 and valve assembly 24 is that valve assembly 206 further includes an end screw 208, a lower septum 210, a lower end cap 212, an upper septum 214, and an upper end cap 216. The use of septums 210, 214 and end caps 212, 216 provides enhanced sealing, particularly for liquids, and low leakage applications of valve assembly 206.

[0056] The lower septum 210 and the upper septum 214 are similar annular plates 218 that include an edge portion 220, a central portion 222 that defines a central opening 224, and an annular bead 226 that extends between the central portion 222 and the edge portion 220. The edge portion 220 transitions toward the central portion 222 to a first annular beveled surface 228 that terminates at the bead 226. A second annular beveled surface 230 extends from the bead 226 to the central portion 222. The use of the bead 226, and the first and second beveled surfaces 228, 230, allows the septums 210 and 214 to flex slightly during use of the valve assembly 206 to assist in sealing the valve assembly 206. In this regard, the use of septums 210, 214, end caps 212, 216, end screw 208, and armature 102 eliminates the need for a sealing member between poppet 28 and valve receiver 26 to keep valve assembly 206 leak-proof.

[0057] By eliminating the need for a sealing member between the poppet 28 and the valve receiver 26, the poppet 28 is furthermore more easily controllable when actuated by the electromagnetic assembly 86, and more proportional control of the valve 200 is achieved. In this regard, no additional force is required to overcome friction between the poppet 28 and the valve receiver 26, as would be required if seal members 64 and 68 were present between the poppet 28 and the valve receiver 26. The septums 210 and 214 may be formed from a rigid, yet flexible, material, such as an elastomeric or polymeric material.

[0058] The edge portion 220 of the lower bulkhead 210 is sandwiched between the lower end cap 212 and the valve receiver 26. In this regard, the lower end cap 212 includes a first cylindrical section 232 having an internally threaded surface 234 that mates with a threaded surface 236 formed on the valve receiver 26. A second cylindrical section 238 having a smaller diameter than the first cylindrical section 232 is connected to the first cylindrical section 232 by a radially inwardly extending abutment surface 240. The abutment surface 240 faces the first end 32 of the valve receiver 26, which, in contrast to the first embodiment of the present disclosure, is open rather than closed. The edge portion 220 is sandwiched between the abutment surface 240 and the open first end 32 of the valve receiver 26.

[0059] A central portion 222 of the lower bulkhead 210 is sandwiched between the proximal end 56 of the poppet 28 and the end screw 208. The end screw 208 includes a threaded shank 242 that extends through the central opening 224 and mates with a threaded opening 244 formed in the proximal end 56 of the poppet 28. A head 246 of the threaded screw 208 extends radially outward from the shank 242, the head extending along the central portion 222 to the second annular angled surface 230. The head 246 includes a recess 248 that is configured to receive a tool (not shown) that can rotate the end screw 208 to mate with the threaded opening 244 of the poppet 28.

[0060] The edge portion 220 of the upper partition 214 is sandwiched between the upper end cap 216 and the valve receiver 26. In this regard, the upper end cap 216 includes a first cylindrical section 250 having an internally threaded surface 252 that mates with a threaded surface 254 formed on the valve receiver 26. A second cylindrical section 256, having a smaller diameter than the first cylindrical section 250, is connected to the first cylindrical section 250 by a radially inwardly extending abutment surface 258. The abutment surface 258 faces the second end 36 of the valve receiver 26. The edge portion 220 is sandwiched between the abutment surface 258 and the second end 36 of the valve receiver 26. It is important to note that in this configuration, the bead 226 of the lower partition 210 extends in a direction opposite to the direction in which the bead 226 of the upper partition 214 extends.

[0061] A central portion 222 of the upper bulkhead 214 is sandwiched between the distal end 58 of the poppet 28 and the radially enlarged shoulder 116 of the armature 102. The armature 102 includes a threaded shank 260 that extends through the central opening 224 and mates with a threaded opening 262 formed in the proximal end 56 of the poppet 28. The radially enlarged shoulder 116 of the armature 102 extends radially outward from the shank 260 and extends along the central portion 222 to the second annular angled surface 230.

[0062] The upper end cap 216 further includes external threads 264 that mate with the internal threads 96 of the adapter bushing 88. Except for the internal threads 96 of the adapter bushing 88, which connect to the external threads 264 of the upper end cap 216, the adapter bushing 88 is the same as that described with respect to the valve arrangement 10. Furthermore, the valve arrangement 200 includes an electromagnetic assembly 86 that includes the same features as the electromagnetic assembly of the valve arrangement 10. That is, the electromagnetic assembly 86 of the valve arrangement 200 includes the lower bushing 118, the leaf spring 140, the electromagnetic housing 132, the coil 134, the electrical lead 154, the upper bushing 156, the post piece 158, and the covering piece 168.

[0063] When a current or voltage is applied to the coil 134, the post 158 ​​becomes magnetized and can magnetically attract the armature 102. When the armature 102 is pulled toward the post 158, the armature 102 pulls the poppet 28 toward the post 158, compressing the leaf spring 140 between the radially enlarged shoulder 116 and the lower bushing 118. When the poppet 28 is pulled toward the post 158, the valve member 60 disengages from the valve seat 62 of the valve receiver 26, opening the valve assembly 206 and allowing fluid to travel from the inlet 16 through the first opening 52, past the valve member 60 toward the distal end 58 of the poppet 28, and through the second opening 54 into the outlet 18. To close the valve assembly 206, the application of current or voltage to the coil 134 is stopped, at which point the leaf spring 140 may urge the armature 102 and poppet 28 away from the post 158. The valve member 60 of the poppet 28 then re-engages with the valve seat 62, closing the valve assembly 206. The functions of the inlet 16 and outlet 18 may be reversed and the valve assembly 206 may still operate in the same manner.

[0064] It should be appreciated that, similar to valve device 10, the combination of the position of adjustable valve seat 30, the magnitude of current or voltage applied to coil 134, and the spring force exerted by leaf spring 140 provides enhanced control over the amount of fluid that can be allowed to pass through valve assembly 206. In other words, the combination of the position of adjustable valve seat 30, the magnitude of current or voltage applied to coil 134, and the spring force exerted by leaf spring 140 controls the distance that valve member 60 can be moved relative to valve seat 62, thereby increasing or decreasing the amount of fluid that can pass through valve assembly 206.

[0065] Furthermore, because the valve assembly 206 further includes the septums 210, 214, end caps 212, 216, and end screw 208, the need for a sealing member between the poppet 28 and the valve receiver 26 is eliminated. Furthermore, by eliminating the need for a sealing member between the poppet 28 and the valve receiver 26, the poppet 28 is more easily controllable when actuated by the electromagnetic assembly 86, and more proportional control of the valve 200 is achieved. In this regard, no additional force is required to overcome friction between the poppet 28 and the valve receiver 26, as would be required if a sealing member were present between the poppet 28 and the valve receiver 26.

[0066] It should also be appreciated that, similar to valve apparatus 10, valve apparatus 200 is a balanced design in which fluctuations in fluid pressure will have no effect on the performance characteristics of valve apparatus 200. In this regard, valve apparatus 200 does not include seals 64, 68, and 84, but rather the balanced design is provided by partitions 210 and 214. More specifically, it should be appreciated that when valve assembly 206 is in the open or closed position, fluid from inlet 16 can be positioned between annular bead 226 of lower partition 210 and poppet 28. Due to annular bead 226 formed by inclined surfaces 228 and 230, lower partition 210 exerts a force perpendicular to inlet 16 and outlet 18 (i.e., along axis X), which balances the fluid force at inlet 16 or outlet 18, respectively, when valve assembly 206 is in the open or closed position. When the valve assembly 206 is in an intermediate open position (i.e., when the valve member 60 of the poppet 28 is neither engaged with the valve seat 62 of the valve receiver 26 nor engaged with the adjustable valve seat 30), the fluid forces exerted at the inlet 16 and outlet 18 balance (i.e., oppose) the forces exerted on the fluid by each of the annular beads 216 of both the partition wall 210 and the partition wall 214. Thus, even when the fluid forces exerted at the inlet 16 and outlet 18 vary, the fluid forces at the inlet 16 and outlet 18 balance the forces exerted by the partition walls 210 and 214, which allows for consistent performance throughout the operating pressure range of the valve apparatus 200.

[0067] Finally, it should be appreciated that each of the valve devices 10 and 200 described above can be modified to have different flow capacities over a wider range of fluid pressures without the need to change the entire structure. More specifically, if the flow rate was to be changed in a particular application, previous valve device designs required structural redesign of the valve device, for example, by changing the bore size, adding springs to balance different flow pressures, or increasing and / or decreasing the size of various components of the valve device. However, the valve devices 10 and 200 of the present disclosure only require slight changes, for example, to the position of the adjustable valve seat 30 or the position of the post 158, to adjust the flow capacity of the valve device.

[0068] In this regard, as noted above, the post 158 ​​is threadably engaged with the housing 132. Thus, the position of the post 158 ​​can be adjusted by adjusting the amount of threaded engagement with the housing 132, thereby allowing for a greater or lesser distance of movement of the poppet 28 when actuated by the solenoid assembly 86. Thus, by adjusting the post 158 ​​in combination with adjusting the position of the adjustable valve seat 30, the valve assemblies 10 and 200 do not need to be structurally redesigned to accommodate different flow outputs over a wider range of pressures.

[0069] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of particular embodiments are not limited to a particular embodiment as a whole, but, where applicable, even if not specifically shown or described, can be substituted and used within selected embodiments. The individual elements or features may also be varied in many ways. Such variations should not be considered a departure from the present disclosure, and all such modifications are intended to be encompassed within the scope of the present disclosure.

Claims

1. A valve, a block having a cavity positioned between the fluid inlet and the fluid outlet; a valve assembly positioned within the cavity for selectively allowing communication between the fluid inlet and the fluid outlet, the valve assembly including a hollow valve receiver having a first port in communication with the fluid inlet, a second port in communication with the fluid outlet, and a valve seat between the first and second ports, the hollow valve receiver housing a movable poppet, the poppet containing a valve member, the valve member configured to engage and disengage with the valve seat to allow fluid to pass from the fluid inlet through the first port to the second port and thereafter to the fluid outlet; an electromagnetic assembly coupled to the valve assembly configured to operate the valve assembly to allow communication between the fluid inlet and the fluid outlet, the electromagnetic assembly including a moveable armature engaged with the poppet, a first bushing surrounding the armature, a leaf spring positioned between the armature and the first bushing, and an electromagnetic coil configured to move the armature and the poppet to allow communication between the fluid inlet and the fluid outlet; and Including, the leaf spring is configured to bias the valve member of the poppet into engagement with the valve seat of the valve receiver and has a spring force; the electromagnetic coil is configured to move the armature and the poppet based on a voltage or a current applied to the electromagnetic coil; The electromagnetic assembly is configured to control the distance the valve member moves relative to the valve seat of the valve receiver based on the spring force of the leaf spring and the voltage or current applied to the electromagnetic coil, thereby proportionally controlling the amount of flow allowed through the valve assembly.

2. 10. The valve of claim 1, wherein the valve assembly further includes an adjustable valve seat, the adjustable valve seat connected to the valve receiver, positioned about the poppet, and including a terminal end, the terminal end engageable with the valve member when the valve member is moved away from the valve seat of the valve receiver.

3. 3. The valve of claim 2, wherein the adjustable valve seat is threadably connected to the valve receiver, and the position of the adjustable valve seat is variable by adjusting the amount of threaded engagement between the adjustable valve seat and the valve receiver.

4. 4. The valve of claim 3, wherein the electromagnetic assembly includes a post having an adjustable position within the electromagnetic assembly, and in combination with adjusting the position of the adjustable valve seat, the valve assembly is configured to provide different flow capacities between the fluid inlet and the fluid outlet.

5. 2. The valve of claim 1, wherein the electromagnetic assembly further includes a second bushing that houses a post piece, the post piece being positioned adjacent to the armature and configured to be magnetized by the coil to attract the armature to open the valve assembly.

6. 2. The valve of claim 1, wherein the leaf spring includes an annular body having a central opening configured to receive the armature and a plurality of auxiliary openings positioned radially outward from the central opening.

7. 2. The valve of claim 1, wherein the first bushing includes a stepped recess configured to receive the leaf spring, the stepped recess including a first annular surface and a second annular surface located radially inward from the first annular surface, and the leaf spring is mounted to the first annular surface.

8. 10. The valve of claim 1, further comprising an adapter bushing configured to connect the electromagnetic assembly to the valve assembly.

9. 2. The valve of claim 1, wherein the valve assembly further includes a first partition located adjacent a first end of the valve retainer and a second partition located adjacent an opposing second end of the valve retainer and adjacent the armature, the first and second partitions being configured to balance fluid pressures exerted at the fluid inlet and the fluid outlet so that fluctuations in fluid pressure exerted at the fluid inlet and the fluid outlet do not affect performance of the valve assembly.

10. 10. The valve of claim 9, wherein each of the first and second septa is formed from an annular plate including an annular bead surrounding a central opening therein, the bead being defined by a first annular beveled surface and a second annular beveled surface.

11. 10. The valve of claim 9, wherein the valve assembly further includes a first end cap mated with a first end of the valve receiver and a second end cap mated with an opposite second end of the valve receiver, the first septum being sandwiched between the first end cap and the first end of the valve receiver, and the second septum being sandwiched between the second end cap and the second end of the valve receiver.

12. 10. The valve of claim 1, further comprising a plurality of sealing members between the poppet and the valve seat, the plurality of sealing members being configured to balance the fluid pressures exerted at the fluid inlet and the fluid outlet so that fluctuations in the fluid pressures exerted at the fluid inlet and the fluid outlet do not affect performance of the valve assembly.

13. A valve, a block having a cavity positioned between the fluid inlet and the fluid outlet; a valve assembly positioned within the cavity for selectively allowing communication between the fluid inlet and the fluid outlet, the valve assembly comprising: a hollow valve receiver having a first end and an opposing second end, a first port in communication with the fluid inlet, a second port in communication with the fluid outlet, and a valve seat between the first port and the second port; a movable poppet located within the valve receiver, the poppet including a valve member configured to engage and disengage with the valve seat to allow fluid to travel from the fluid inlet through the first port to the second port and then to the fluid outlet; an adjustable valve seat coupled to the valve receiver, positioned about the poppet, and including a terminal end engageable with the valve member when the valve member is moved away from the valve seat of the valve receiver; and a first partition located adjacent to a first end of the valve receiver; a second partition located adjacent the second opposing end of the valve receiver; and a first end cap mated with the first end of the valve receiver; a second end cap mated with the opposing second end of the valve receiver; and It encompasses a valve assembly, the first septum sandwiched between the first end cap and the first end of the valve receiver, and the second septum sandwiched between the second end cap and the second end of the valve receiver; an electromagnetic assembly coupled to the valve assembly configured to operate the valve assembly to allow communication between the fluid inlet and the fluid outlet, the electromagnetic assembly including a moveable armature engaged with the poppet, a first bushing surrounding the armature, a leaf spring positioned between the armature and the first bushing, and an electromagnetic coil configured to move the armature and the poppet to allow communication between the fluid inlet and the fluid outlet; and Including, the leaf spring is configured to bias the valve member of the poppet into engagement with the valve seat of the valve receiver and has a spring force; the electromagnetic coil is configured to move the armature and the poppet based on a voltage or a current applied to the electromagnetic coil; The electromagnetic assembly is configured to control the distance the valve member moves relative to the valve seat of the valve receiver based on the spring force of the leaf spring and the voltage or current applied to the electromagnetic coil, thereby proportionally controlling the amount of flow allowed through the valve assembly.

14. 14. The valve of claim 13, wherein the adjustable valve seat is threadably coupled to the valve receiver, and the position of the adjustable valve seat is variable by adjusting the amount of threaded engagement between the adjustable valve seat and the valve receiver.

15. 15. The valve of claim 14, wherein the electromagnetic assembly includes a post having an adjustable position within the electromagnetic assembly, and in combination with adjusting the position of the adjustable valve seat, the valve assembly is configured to provide different flow capacities between the fluid inlet and the fluid outlet.

16. 14. The valve of claim 13, wherein the electromagnetic assembly further includes a second bushing that houses a post piece, the post piece being positioned proximate to the armature and configured to be magnetized by the coil to attract the armature to open the valve assembly.

17. 14. The valve of claim 13, wherein the leaf spring includes an annular body having a central opening configured to receive the armature and a plurality of auxiliary openings positioned radially outward from the central opening.

18. 14. The valve of claim 13, wherein the first bushing includes a stepped recess configured to receive the leaf spring, the stepped recess including a first annular surface and a second annular surface located radially inward from the first annular surface, the leaf spring mounted to the first annular surface.

19. 14. The valve of claim 13, further comprising an adapter bushing configured to connect the electromagnetic assembly to the valve assembly.

20. 14. The valve of claim 13, wherein each of the first and second septa is formed from an annular plate including an annular bead surrounding a central opening therein, the bead being defined by a first annular beveled surface and a second annular beveled surface.

21. 14. The valve of claim 13, wherein the first and second partitions are configured to balance fluid pressures exerted at the fluid inlet and fluid outlet so that fluctuations in the fluid pressures exerted at the fluid inlet and fluid outlet do not affect performance of the valve assembly.

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