Poppet-type valve configuration

Abstract

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

Description

[Technical Field]

[0001] Cross-reference of related applications This application claims priority and all interests of U.S. Provisional Patent Application No. 63 / 180,186 (POPPET-STYLE VALVE ARRANGEMENTS), filed on 27 April 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to a fluid flow device and a fluid delivery device, and to a fluid flow method and a fluid delivery method, and more specifically to a poppet valve used to control fluid flow and fluid delivery. [Background technology]

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

[0004] According to exemplary embodiments of the present disclosure, a valve seat carrier subassembly includes an annular valve seat carrier body including an annular projection extending radially within a central passage, and an annular plastic seal ring overmolded on the annular projection, the annular plastic seal ring defining a valve seat seal.

[0005] According to another exemplary embodiment of the present disclosure, the valve assembly includes a valve body defining a flow path between an inlet port and an outlet port, an annular seal ring surrounding an axial extension of the flow path between the inlet port and the outlet port, and a poppet assembled with the valve body and axially movable between a closed position and an open position. The seal ring interlocks with a projection extending radially within the flow path.

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

[0007] According to another exemplary embodiment of the present disclosure, the poppet portion assembly includes a poppet having a central portion positioned between an axially extending upper stem portion and a lower stem portion, the central portion defining an upwardly extending radial seal portion and a downwardly extending radial shoulder portion, a retaining clip fixed above an enlarged foot portion of the lower stem portion, and a poppet spring positioned around the lower stem portion and captured between the shoulder portion and the retaining clip.

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

[0009] According to another exemplary embodiment of the present disclosure, the pressure regulator includes at least one of the following: a valve module having a valve housing block for holding a poppet and a valve seat seal; a load module having a load block fixed adjacent to a vent adapter block and configured to hold a load element configured to apply a load force to a sensing member positioned between a load element and a poppet; a piston module having a piston adapter block fixed between the valve housing block and the load block and for engaging and holding a sensing member with a poppet, wherein the sensing member has a piston; and a vent module having a vent adapter block fixed between the valve housing block and the load block and defining a vent port that is in fluid communication with a vent passage in the sensing member. The valve housing block and at least one of the piston adapter block and vent adapter block each include a uniformly sized first assembly interface, and the load block and at least one of the piston adapter block and vent adapter block each include a uniformly sized second assembly interface that mates and seals with the first assembly interface of the adjacent valve housing block and at least one of the piston adapter block and vent adapter block, so that the valve housing block is configured to be assembled directly to the load block by omitting each of the piston module and vent module.

[0010] According to another exemplary embodiment of the present disclosure, the pressure regulator includes a valve body that holds a valve seat; a poppet disposed within the valve body and movable axially relative to the valve seat; a spring load mechanism assembled with the valve body and operable to apply a downward load force; and a sensing element disposed between the spring load mechanism and the poppet for transmitting the load force from the spring load mechanism to the poppet. The spring load mechanism includes a spring housing; a spring element held within the spring housing and disposed between an upper force adjustment plate and a lower spring bearing plate; and an adjustment handle assembled with the spring housing and including a threaded stem portion that screws into the upper force adjustment plate. The upper force adjustment plate is rotatably fixed within the spring housing and axially slidable so that when the user rotates the adjustment handle, the upper force adjustment plate moves axially and the downward load force is adjusted. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic cross-sectional view of a poppet-type valve assembly. [Figure 2A] This is a schematic cross-sectional view of the pressure reducing valve assembly. [Figure 2B] This is a cross-sectional view of the back pressure regulating valve assembly. [Figure 3] This is a cross-sectional view of a pressure reducing valve subassembly according to an exemplary embodiment of the present disclosure. [Figure 3A] Figure 3 is a perspective view of the poppet assembly of the regulating valve assembly. [Figure 4] This is a cross-sectional view of a back pressure regulating valve subassembly according to an exemplary embodiment of the present disclosure. [Figure 4A] Figure 4 is a perspective view of the poppet and sensing mechanism bearing member assembly of the adjustment valve assembly. [Figure 5A] This is a cross-sectional view of a valve seat carrier subassembly according to an exemplary embodiment of the present disclosure. [Figure 5B] Figure 5A is an exploded top perspective view of the valve seat carrier subassembly. [Figure 5C] Figure 5A is a downward exploded perspective view of the valve seat carrier subassembly. [Figure 6A]Cross-sectional view of a valve seat carrier sub-assembly according to another exemplary embodiment of the present disclosure. [Figure 6B] Upper exploded perspective view of the valve seat carrier sub-assembly of FIG. 6A. [Figure 6C] Lower exploded perspective view of the valve seat carrier sub-assembly of FIG. 6A. [Figure 7] Cross-sectional view of a pressure reducing valve with a diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 8] Cross-sectional view of a back pressure regulating valve with a diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 9] Cross-sectional view of a pressure reducing valve with a high-sensitivity diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 10] Cross-sectional view of a back pressure regulating valve with a high-sensitivity diaphragm sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 11] Cross-sectional view of a pressure reducing valve with a piston sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 12] Cross-sectional view of a back pressure regulating valve with a piston sensing mechanism according to another exemplary embodiment of the present disclosure. [Figure 13] Cross-sectional view of a spring load mechanism of a pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 13A] Exploded perspective view of the spring load mechanism of FIG. 13. [Figure 14] Cross-sectional view of a dome load mechanism of a diaphragm sensing pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 15] Cross-sectional view of a dome load mechanism of a piston sensing pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 16] Cross-sectional view of a self-venting diaphragm sensing mechanism of a pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 17] Cross-sectional view of a self-venting piston sensing mechanism of a pressure regulating valve assembly according to another exemplary embodiment of the present disclosure. [Figure 18] This is a perspective view of a modular piston sensing, venting, and spring load reduction regulator assembly according to an exemplary embodiment of the present disclosure. [Figure 19] Figure 18 is a cross-sectional view of the modular tuner assembly. [Figure 19A] This is an enlarged view of the area labeled 19A in Figure 19. [Figure 20] Figure 18 is an exploded perspective view of the regulator assembly. [Figure 21] This is a cross-sectional view of a modular diaphragm sensing, venting, and spring load reduction regulator assembly according to an exemplary embodiment of the present disclosure. [Figure 22] This is a cross-sectional view of a modular piston sensing, non-vented, spring load reduction regulator assembly according to an exemplary embodiment of the present disclosure. [Figure 23] This is a cross-sectional view of a modular diaphragm sensing, non-vented, spring load reduction regulator assembly according to an exemplary embodiment of the present disclosure. [Figure 24] This is a perspective view of a modular diaphragm sensing, non-vented, spring-loaded back pressure regulator assembly according to an exemplary embodiment of the present disclosure. [Modes for carrying out the invention]

[0012] The embodiments for carrying out this invention are merely illustrative and not intended to limit the claims in any way. In fact, the claimed invention is broader than and not limited by the exemplary embodiments, and the terms used in the claims have their usual meanings. For example, while the specific embodiments described herein relate to the configuration of pressure reducing and back pressure regulating valves, the features of the present application may be applied, in addition or alternatively, to other types of valves, including, for example, user-operable regulating valves, shut-off valves, check valves, and relief valves. The terms “poppet valve” and “poppet-type valve” as used herein are intended to broadly include any valve including a stem that carries a flow limiting member, which moves relative to an annular valve seat by longitudinal movement of the stem and may, but does not have to, be movable in a sealed engagement with the valve seat. The terms “seal” and “seal engagement” are intended to include, in addition to being leak-free or fluid-sealing, a state of reduced flow due to contact between the sealing surface and the seating surface.

[0013] Various aspects, concepts, and features of the present invention may be described and illustrated herein as being embodied in combination in exemplary embodiments, but these various aspects, concepts, and features may be used individually or in various combinations and partial combinations in many alternative embodiments. Unless expressly excluded herein, all such combinations and partial combinations are intended to be within the scope of the present invention. Furthermore, various alternative embodiments relating to various aspects, concepts, and features of the present invention may be described herein, including alternatives relating to alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, formation, fit and function, but such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether currently known or to be developed in the future. Those skilled in the art will readily be able to adopt one or more aspects, concepts, or features of the present invention in additional embodiments and uses within the scope of the present invention, even if such embodiments are not expressly disclosed herein. Furthermore, some features, concepts, or aspects of the present invention may be described herein as preferred mechanisms or methods, but such descriptions are not intended to suggest that such features are required or necessary unless expressly stated otherwise. Furthermore, while illustrative or representative values ​​and ranges may be included to aid in understanding this disclosure, such values ​​and ranges should not be interpreted restrictively and are intended to be critical values ​​or ranges only when explicitly stated as such. Parameters identified as “approximately” or “about” a particular value are intended to include both the specific value and values ​​within 10% of that value, unless otherwise specified. Additionally, while the drawings accompanying this application may be, but do not need to be, certain ratios, it should be understood that they may be interpreted as teaching various ratios and proportions that are evident in the drawings.Furthermore, various aspects, features, and concepts may be expressly identified herein as inventive or forming part of an invention, but such identification is not intended to be exclusive. Rather, there may be aspects, concepts, and features of the invention fully described herein that are not expressly identified in such way or as part of a particular invention, and instead, the present invention is described in the appended claims. Illustrative descriptions of methods or processes are not limited to including all steps as necessary in all cases, nor is the order in which the steps are presented necessarily or required unless expressly stated otherwise.

[0014] Referring to Figure 1, in the schematically shown exemplary embodiment, the poppet 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 that extends axially in 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 or load mechanism 50, when assembled with the poppet stem 41, controls the axial movement of the poppet 40 between a closed position in which the poppet seal portion 42 seals the valve seat 30 (for example, to prevent flow rates exceeding an allowable leakage rate) and an open position in which the poppet seal portion axially separates from the valve seat, allowing fluid to flow through the axial extension 24 of the valve passage 22. The actuator 50 may be operable by a user (for example, manually, pneumatically, or electrically) for selective movement of the poppet 40. Alternatively, the actuator 50 may be configured to automatically move the poppet under specific, predetermined system conditions, or to enable the movement of the poppet. For example, the actuator configuration may be configured to cause or enable the automatic movement of the poppet 40 at a threshold of system flow pressure, for example, to release excess flow 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 configuration is disclosed in a product catalog titled PRESSURE REGULATORS RHPS SERIES, which is publicly available online and otherwise from Swagelok Company and is incorporated herein by reference in full.

[0015] Figure 2A schematically shows a pressure regulator 10a having an adjustment mechanism including a sensing element 80a (e.g., a piston or diaphragm), which is subjected to a load force F applied by a load mechanism 50a (e.g., a compressed spring or fluid pressurizing chamber) for the downward biasing motion of the poppet 40a. Sreceives it on the upper side. When the lower side of the sensing element 80a receives the force F of the system fluid, when the system fluid force F exceeds the biasing element load gravity F S , the poppet 40a moves upward (e.g., by direct attachment of the poppet or separately driven movement). The load gravity F S biases the poppet 40a towards an open position away from the sealing engagement with the valve seat 32a. When the downstream flow pressure exceeds the desired pressure corresponding to the system fluid force F exceeding the biasing element load gravity F S , when the sensing element 80a moves upward, the poppet moves upward towards the closed position with respect to the valve seat 32a, reducing the outlet pressure. When the downstream flow pressure reduces below the desired pressure, the biasing element load gravity F S overcomes the system fluid force F, the sensing element 8 moves downward, and the poppet 40a moves downward towards the open position.

[0016] FIG. 2B schematically shows a back pressure regulator 10b similar to the pressure reducing regulator 10a of FIG. 2A having an adjustment mechanism including a sensing element 80b (e.g., a piston or diaphragm), which receives on the upper side a load gravity F applied by a load mechanism 50b (e.g., a compressed spring or a fluid pressurized chamber) for the downward biasing movement of the poppet 40b. S The lower side of the sensing element 80b receives the force F of the system fluid, so that when the system fluid force F exceeds the load mechanism load gravity F S , the poppet 40b moves upward. The load gravity F S biases the poppet 40b towards a closed position of sealing engagement with the valve seat 32b. When the upstream flow pressure exceeds the desired pressure corresponding to the system fluid force F exceeding the load mechanism load gravity F S , when the sensing element 80b moves upward, the poppet moves upward towards the open position with respect to the valve seat 32b, reducing the inlet or upstream pressure. When the upstream flow pressure reduces below the desired pressure, the load mechanism load gravity F S overcomes the system fluid force F, the sensing element 80b moves downward, and the poppet 40b moves downward towards the closed position.

[0017] Many different configurations of regulator valve bodies, poppets, and seats may be used in various combinations. Figure 3 shows an exemplary pressure reducing valve subassembly 101, which includes a regulator valve body 110 defining a valve passage 112 between an inlet port 111 and an outlet port 113, and an annular valve seat sealing surface 132 located within a central cavity 114 extending axially from the valve body between the inlet and outlet ports. The poppet 140 is assembled with the valve body 110 and includes an upper poppet stem 141 extending axially to engage (directly or indirectly) with a sensing element, and a radially extending poppet seal portion 142, the poppet being axially movable between a lower open position where the poppet seal portion is axially separated from the valve seat sealing surface 132 and an upper closed position where the poppet seal portion is tightly engaged with the valve seat sealing surface. The outlet port 113 is in fluid communication with a sensing interface chamber 119, which is at least partially defined by the upper end of the valve body 110. In this configuration, a downward force (described in detail below) applied to the poppet 140 through a sensing mechanism that exceeds the upward force applied by the outlet flow pressure moves the poppet toward the lower open position.

[0018] In the illustrated example, the valve body 110 includes a main housing 115 and a main plug 120 assembled (e.g., screwed) to a central cavity 114 of the housing, and the valve seat sealing surface 132 is positioned on a valve seat carrier 130 that is held within the central cavity of the housing.

[0019] As shown in Figure 3, the main housing 115 may be provided with a support ring 105 sized to support the adjuster in an upright position (e.g., on a workbench) before installation. The support ring 105 may be made of flexible plastic (e.g., nylon) to facilitate snap-on (and snap-off) engagement with the lower lip 115-1 on the main housing 115. During installation, the support ring 105 may be removed or retained with the adjuster, for example, as a visual indicator (e.g., color code, text, or symbol). In other embodiments, the support ring may provide mounting for additional hardware or devices. For example, as shown in Figure 7, a heater block 102 (or other fixture block) may be secured to the support ring 105 by using threaded fasteners 106, which are installed through a mounting aperture 107 in the support ring and screwed into a mounting hole 103 in the heater block 102.

[0020] An exemplary body plug 120 includes a central cavity 121 for receiving the lower stem portion 143 of the poppet 140, an upper end surface 122 for engaging with the valve seat carrier 130 and securing the valve seat carrier against a first counterbore 116 of the central cavity 114, and one or more apertures 123 positioned to align with the valve body inlet port 111 when the poppet 140 is in the open position, thereby allowing fluid to flow from the inlet port into the body plug cavity 121, between the poppet seal portion 142 and the valve seat seal surface 132, and to the outlet port 113. The apertures 123 can be circumferentially spaced around the body plug 120 to ensure that the inlet port 111 aligns with at least one of the apertures regardless of the rotational position of the body plug within the valve body housing 115. The valve seat carrier 130 may be provided with an outer annular groove 133 for retaining a gasket or O-ring seal 134 for tight engagement with the first counterbore 116. The main plug end face 122 may be configured to engage with a second counterbore 117 in the central cavity 114, for example, to limit axial compression of the valve seat carrier 130.

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

[0022] To facilitate the assembly of the pressure reducing valve subassembly 101, the poppet spring 146 may be pre-assembled with the poppet subassembly 140 as a poppet subassembly, for example, in an uncompressed or partially compressed state, thereby allowing the threads of the body plug to initially engage with the threads of the housing without the need to compress the spring. When the body plug 120 is partially screwed into the central cavity 114, the body plug is fully screwed into the central cavity, completing the desired compression of the poppet spring 146, and the end face 122 of the body plug engages with the second counterbore 117, providing a hard stop to the screwing. Many different configurations can be used to provide the pre-assembled spring to the poppet, but in the illustrated embodiment, as clearly shown in Figure 3A, an e-shaped clip or other such retaining clip 109 is fixed above the enlarged foot 148 of the lower poppet stem 143, providing the lower bearing surface of the poppet spring 146. The spring 146 may, but is not required to be, pre-pressed or spring-loaded between the poppet shoulder 144 and the retaining clip 109. The body plug cavity 121 may include a shallow annular recess or counterbore 124 made to a size for receiving and aligning the retaining clip 109.

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

[0024] Figure 4 shows an exemplary back pressure regulating valve subassembly 201, which includes a regulator valve body 210 defining a valve passage 212 between an inlet port 213 and an outlet port 211, and an annular valve seat sealing surface 232 located within a central cavity 214 extending axially from the valve body between the inlet and outlet ports. The poppet 240 is assembled with the valve body 210 and includes an upper poppet stem 241 extending axially to engage (directly or indirectly) with a sensing mechanism, and a radially extending poppet seal portion 242, the poppet being axially movable between a lower closed position in which the poppet seal portion engages tightly with the valve seat sealing surface 232 and an upper open position in which the poppet seal portion is axially separated from the valve seat seal. The inlet port 213 is in fluid communication with a sensing interface chamber 219, which is at least partially defined by the upper end of the valve body housing 215. In this configuration, a downward force (described in more detail below) applied to the poppet 240 through a sensing mechanism that exceeds the upward force applied by the inlet flow pressure moves the poppet toward the lower closed position.

[0025] The valve body may be provided as a single piece or monolithic component, including an integrally formed valve seat, but in other embodiments, the valve body may include multiple component assemblies to facilitate the installation and / or replacement of, for example, poppets, valve seats, or other such components. In the illustrated example, the valve body 210 includes a valve housing 215 and a body plug 220 assembled (e.g., screwed) to a central cavity 214 of the housing, and the valve seat sealing surface 232 is positioned on a valve seat carrier 230 retained within the central cavity of the housing.

[0026] An exemplary body plug 220 includes a central cavity 221 for receiving the lower stem portion 243 of a poppet 240, an upper end surface 222 for engaging with a valve seat carrier 230 and securing the valve seat carrier against a first counterbore 216 of the central cavity 214, and one or more apertures 223 positioned such that when the poppet 240 is in the open position, the fluid can enter the body plug cavity 221 from the inlet port 213, through the poppet seal portion 242 and the valve seat seal surface 232, and flow through the apertures 223 to the outlet port 211. The apertures 223 can be circumferentially spaced around the body plug 220 to ensure that the outlet port 211 is aligned with at least one of the apertures, regardless of the rotational position of the body plug in the valve housing 215. The valve seat carrier 230 may be provided with an annular end face groove 235 for retaining a gasket / O-ring seal 236 for tight engagement with the first counterbore 216. The main plug end face 222 may be configured to engage with a second counterbore 217 in the central cavity 214, for example, to limit axial compression of the valve seat carrier 230.

[0027] As shown in the figure, the poppet 240 may be provided with an internal passage 245 extending from the lower stem portion 243 of the poppet to the upper part of the poppet upstream of the valve seat sealing surface 232, and a gasket seal 247 provides a seal between the enlarged lower foot portion 248 of the lower stem portion of the poppet and the narrower base portion 225 of the main plug cavity 221, so that when the poppet 240 is in the closed position, the inlet or upstream flow pressure acting on the poppet is offset by the outlet or downstream flow pressure. This configuration is sometimes called a balanced poppet design, which can result in, for example, a reduction in seat load and, for example, a reduction in seat wear / deformation.

[0028] In the back pressure regulating valve assembly, the seat may be further protected from excessive poppet closing force applied by the sensing mechanism by an overtravel spring positioned between the sensing mechanism and the poppet seal, thereby allowing the sensing mechanism to advance further downward axially when engaging the poppet seal with the valve seat seal. According to exemplary embodiments of the present disclosure, the poppet may be interlocked with a bearing member of the sensing mechanism using a joint, which may be configured to restrict the axial movement of the poppet relative to the sensing mechanism bearing member while the overtravel spring is trapped between the opposing surfaces of the poppet and the sensing mechanism bearing member. This joint configuration facilitates assembly of the poppet with the sensing mechanism.

[0029] While many different joint configurations can be used, in an exemplary embodiment, one of the poppet and the bearing member is provided with an enlarged or flanged head, and the other of the poppet and the bearing member includes a grooved socket portion, which holds the head in place when the overtravel spring is compressed between the poppet and the bearing member portion, such that the overtravel spring biases the seal portion of the poppet away from the bearing member. When the load force of the sensing mechanism moves the poppet to the closed position, excessive closing force from the sensing mechanism is limited by compressing the overtravel spring between the poppet and the bearing member, thereby limiting the closing force that the poppet exerts on the valve seat seal.

[0030] In the illustrated example, as also shown in Figure 4A, the enlarged or flanged head 249 of the poppet 240 is received in the grooved socket portion 289 of the sensing mechanism bearing member 282, and the overtravel spring 246 is compressed between the lower end surface 287 of the bearing member and the upper shoulder portion 244 of the poppet 240, thereby biasing the seal portion 242 of the poppet away from the bearing member. When the load force of the sensing mechanism moves the poppet 240 to the closed position, the excessive closing force from the sensing mechanism is limited by compressing the overtravel spring 246 between the poppet and the bearing member 282, thereby limiting the closing force that the poppet applies to the valve seat seal surface 232.

[0031] In an exemplary method, to assemble the valve seat carrier 230, poppet 240, and body plug 220 with the valve body housing 215 of the back pressure regulating valve configuration 201, the overtravel spring 246 is compressed between the poppet and the bearing member by sliding the overtravel spring 246 above the upper poppet stem 241 and installing the head 249 of the poppet into the grooved socket portion 289 of the sensing mechanism bearing member 282. The poppet 240 is installed into the housing 215 by passing it through the upper end of the central cavity 214, and the valve seat carrier 230 is installed into the housing by passing it through the lower end of the central cavity 214. The body plug 220 is placed on the lower poppet stem 243 and screwed into the valve body housing 215, fixing the valve seat carrier 230 to the first counterbore 216.

[0032] For example, many different types of valve seat carrier assemblies can be utilized to accommodate different system pressures, temperatures, and fluid / chemical properties. In the exemplary embodiments shown in Figures 3 and 4, the valve seat carriers 130, 230 include annular single-piece valve seats 131, 231 having a contoured inner diameter defining the valve seat sealing surfaces 132, 232. The valve seat carriers 130, 230 may be supplied in any suitable material, including plastics such as polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), and polyetheretherketone (PEEK). In the pressure reducing valve subassembly 101, the valve seat carrier includes an outer annular groove 133 that retains a gasket seal 134 for sealed engagement with a first counterbore 116. In the back pressure regulating valve subassembly 201, the valve seat carrier 230 includes an annular end face groove 235 that retains a gasket seal 236 for sealed engagement with a first counterbore 216.

[0033] In some applications, such as high-pressure and / or high-temperature applications, using harder materials (e.g., materials with a hardness of at least 90 SHORE D), such as metal (e.g., stainless steel), for the seat and seal portions can make valve seat leaks much more likely due to reasons such as misalignment, surface mismatch, contamination, or wear of the valve seat seal. Particularly at high pressure, even small leaks can cause erosion of the sealing surface, potentially leading to even greater leaks beyond the valve seat. Furthermore, in some valve assemblies, the closing force applied to the poppet stem may be minimal and insufficient to compensate for misalignment of the sealing surface, causing the valve seat and seal portions to flex or deform.

[0034] According to one aspect of the present disclosure, the valve seat may be provided as an annular, more flexible material (e.g., having a hardness of less than about 100 HRB) seal ring that interlocks with or is fixed to or resting on a harder (e.g., harder than about 80 HRB) inner rib, flange, rail, or other such projection protruding into the central portion of the valve passage. The projection below the rigidity allows for the use of a relatively thin (e.g., between about 0.05 inches and about 0.10 inches) seal ring, while providing rigid support to facilitate use in high-pressure applications (e.g., up to about 6000 psi), thereby minimizing thermal expansion, material flow, and deformation of the softer seal ring material.

[0035] Figures 5A, 5B, and 5C show an exemplary annular valve seat carrier subassembly 330 similar to the valve seat carriers 130 and 230 of Figures 3 and 4, including a valve seat carrier body 331, the valve seat carrier body including an inner circumferential annular projection 338 and an annular seal ring 337 overmolded, overlaid, or otherwise interlocked onto the annular projection. The seal ring 337 defines a valve seat seal surface 332 having a contour for sealed engagement with a poppet seal portion (as shown, for example, in Figures 3 and 4). Various projections can be utilized, but in the illustrated embodiment, the projection 338 is formed as an annular, circumferentially continuous, substantially T-shaped rail, which includes a narrower neck and an enlarged head shaped to interlock and retain with a channel portion 339 made to complement the shape of the seal ring 337. In other embodiments, the protrusions may have different cross-sectional shapes and / or be discontinuous in the circumferential direction, for example, by varying the cross-sectional shape around the circumferential direction, or by being formed from two or more segments spaced apart in the circumferential direction.

[0036] Similar to the seal rings 130 and 230 in Figures 3 and 4, the valve seat carrier 330 may include a first annular groove 333 (e.g., an outer annular groove) that holds a gasket seal 334 for tightly engaging with a recess inside the valve body (e.g., a recess 116 in the pressure-reducing valve subassembly 101 in Figure 4) and provides a downward-facing valve seat seal surface 332, and / or a second annular groove 335 (e.g., an annular end face groove 335) that holds a gasket seal 336 for tightly engaging with a recess inside the valve body (e.g., a recess 216 in the back pressure-regulating valve subassembly 201 in Figure 4) and provides an upward-facing valve seat seal.

[0037] The seal ring may be assembled onto the projection by press-fitting or other methods, but in other embodiments, the seal ring 337 may be injection-molded or overmolded onto the annular projection 336, thereby providing consistency in the roundness, surface finish, and material thickness of the seal ring. Various injection molding methods can be used. In an exemplary configuration, injection molding using a diaphragm gate located at a noncritical position g of the inner diameter of the seal ring, spaced away from the contoured seal surface 332, can prevent injection molding streamlines and the resulting uneven shrinkage and inconsistent roundness of any seal ring.

[0038] In yet another embodiment, additive manufacturing (e.g., 3D printing) can be used to form a seal ring on the underlying protrusion. Examples of available additive manufacturing techniques include, for example, laser powder bed fusion (direct metal laser sintering or "DMLS", selective laser sintering / melting or "SLS / SLM", or layered additive manufacturing or "LAM"), electron beam powder bed fusion (electron beam melting or "EBM"), ultrasonic additive manufacturing ("UAM"), or direct energy deposition (laser powder deposition or "LPD", laser wire deposition or "LWD", laser-operated net shaping or "LENS", or electron beam wire deposition).

[0039] Any suitable material can be used to provide adequate sealing performance within the valve. For example, the seal ring may be made of a suitable plastic (e.g., PEEK), and the seal ring retaining projection may be made of metal (e.g., stainless steel). The gasket / O-ring seal may be formed from a suitable elastomer (e.g., ethylene propylene diene monomer (EPDM), perfluoroelastomer, or nitrile).

[0040] In other embodiments (not shown), the seal ring retaining projection is formed integrally with the valve body (for example, as a projection into the valve body channel), thereby eliminating a separate valve seat carrier component.

[0041] According to another aspect of this disclosure, the valve seat seal may be defined by an elastomer gasket or O-ring to provide an effective seal, for example, in lower pressure applications (e.g., less than about 1000 psi). The O-ring / gasket valve seat seal may be transported by a poppet, but in other embodiments, the valve seat carrier configuration may be configured to fix and hold the O-ring gasket seal to provide the valve seat seal on a poppet (e.g., a single poppet). In exemplary embodiments, the valve seat carrier may include separate first ring components and separate ring components assembled (e.g., loosely assembled) on top of the O-ring seal, with a portion of the O-ring seal exposed within an inner diameter gap between the inner edges of the first and second ring components. By limiting the exposure of the O-ring seal, extrusion, contact, or other damage to the O-ring during valve operation can be minimized.

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

[0043] In the illustrated embodiment, the first outer ring component 431-1 includes a flange 461 extending radially inward defining an inner counterbore 462, and a flange 463 extending axially upward (in the orientation shown in Figure 6A) defining an outer counterbore 464. The second inner ring component 431-2 includes an outer peripheral portion 465 seated within the outer counterbore 464 of the outer ring component 431-1, and a flange 466 extending axially downward toward the radially inward extending flange 461 of the outer ring component, defining an annular cavity 467 of the O-ring seal and inner diameter gap 468.

[0044] Similar to the seal rings 130, 230, and 330 in Figures 3, 4, and 5A to 5C, the valve seat carrier 430 may also include a first annular groove 433 (e.g., an outer annular groove) that holds a gasket seal 434 for a sealed engagement with a recess inside the valve body (e.g., a recess 116 in the pressure-reducing valve subassembly 101 in Figure 3) and provides a downward-facing valve seat seal 432, and / or a second annular groove 335 (e.g., an annular end face groove) that holds a gasket seal 436 for a sealed engagement with a recess inside the valve body (e.g., a recess 216 in the back pressure-regulating valve subassembly 201 in Figure 4) and provides an upward-facing valve seat seal.

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

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

[0047] According to another aspect of the present disclosure, one or more control valve subassembly components may be configured to facilitate modular interchangeability of components in a plurality of control assemblies, for example, including different flow control configurations (e.g., pressure reduction, back pressure control), different types of valve seat seals (e.g., rigid plastic, soft elastomer), different load mechanisms (e.g., spring load and / or dome load mechanisms), different control sensor mechanisms (e.g., diaphragm sensor mechanism, piston sensor mechanism), and other optional features (e.g., self-vent configuration).

[0048] For example, as shown in Figures 3 and 4, the valve body (e.g., valve body housing 115 / 215 and valve body plug 120 / 220) may be configured for use with both pressure reducing and back pressure regulating valves. As shown, the first port 111 / 211 of the valve body housing 115 / 215 functions as the inlet port of the pressure reducing valve (Figure 3) and the outlet port of the back pressure regulating valve (Figure 4), while the second port 113 / 213 of the valve body housing functions as the outlet port of the pressure reducing valve and the inlet port of the back pressure regulating valve. To accommodate the enlarged head socket joint of the back pressure regulating valve configuration (described in more detail above), the central cavity 114 / 214 of the valve body housing 115 / 215 may be provided with an enlarged upper recess 118 / 218 made to accommodate the grooved socket portion 289 and the lower end face 287 of the bearing member 282. To guide the upper poppet stem 141 of the pressure reducing valve configuration, a guide ring 170 is housed in an enlarged upper recess 118 / 218 so that the upper poppet stem can be tightly received. Many different guide rings may be available, but in the illustrated embodiment, the guide ring 170 includes first and second annular guide ring elements 171, 172 that capture an O-ring 173 providing a guide seal for the upper poppet stem 141. The enlarged upper recess 118 / 218 and the first guide ring element 171 may include a screw that fits to screw and secure the guide ring 170 within the valve body housing 115. As shown, the valve body housing 115 / 215 may include a bypass channel 113-1 / 213-1 extending from a second port 113 / 213 to a sensing interface chamber 119 / 219 to pressurize the sensing mechanism within the pressure reducing valve configuration.

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

[0050] For example, in applications with lower outlet pressures (e.g., spring load assemblies used with outlet pressures up to approximately 600 psi), and in applications where it is desirable to sense changes in outlet pressure with greater precision, the diaphragm sensing mechanism used can be adapted for use with modular pressure reducing valve configurations and back pressure regulating valve configurations, as described herein.

[0051] In the embodiment shown in Figure 7, the diaphragm sensing mechanism 580, shown together with the pressure reducing valve subassembly 101 of Figure 3, includes a flat, flexible disc of a material (e.g., an elastomer, plastic, or metal suitable for the system fluid) forming the diaphragm 581, the diaphragm having an outer circumference that is clamped or fixed between the body surfaces (e.g., between the opposing surfaces of the valve housing block 115 and the spring or dome load housing block, fastened by a screw configuration). As shown, the diaphragm sensing mechanism 580 may also include a diaphragm screw or bearing member 582, which, when installed through a central opening in the diaphragm 581, can more robustly engage the diaphragm with the poppet 140 and the load mechanism (described later), for example, to protect the diaphragm from damage. In the illustrated example, the upper and lower plates 583 and 584 are fixed to the diaphragm screw 582 on both sides of the diaphragm 581 by nuts 585 that are screwed onto the diaphragm screw, further supporting the diaphragm.

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

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

[0054] In the embodiment shown in Figure 9, the high-sensitivity diaphragm sensing mechanism 780, shown together with the pressure reducing valve subassembly 101 of Figure 3, includes an enlarged diaphragm 781, which has an outer circumference clamped or fixed between an upper diaphragm shell member 781-1 and a lower diaphragm shell member 781-2, which may be fixed to each other by a screw configuration or bolted to the valve body housing block 115 (through mounting holes into the lower diaphragm shell member). As shown, the diaphragm sensing mechanism 780 may also include a diaphragm screw or bearing member 782, which, when installed through a central opening in the diaphragm 781, can more robustly engage the diaphragm with the poppet 140 and the load mechanism (described later), for example, to protect the diaphragm from damage. In the illustrated example, the upper and lower plates 783 and 784 are fixed to the diaphragm screw 782 on both sides of the diaphragm 781 by nuts 785 screwed onto the diaphragm screw, further supporting the diaphragm.

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

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

[0057] In the embodiment shown in Figure 11, the piston sensing mechanism 980, shown together with the pressure reducing valve subassembly 101 of Figure 3, includes an axially elongated piston member 982, which is received in a central piston bore 984 of a piston adapter plate or block 983 fixed between body surfaces (for example, between opposing surfaces of the valve body housing block 115 and the spring or dome load housing block, fastened together by a screw configuration). While many different types of sensing piston members may be used, in the illustrated embodiment, the piston member 982 includes a stepped configuration, allowing the fluid-driven load applied to the piston to be adjusted by selecting a stepped diameter on which O-ring seals 988-1, 988-2, and 988-3 are provided, thereby allowing the piston top surface on which the fluid pressure acts to fluctuate. The central piston bore 984 of the piston adapter block 983 is made to be the size and shape necessary to accommodate this stepped piston configuration. Furthermore, since the lower end of the piston adapter block 983 can be shaped to match the upper end of the valve housing 115 / 215, the same valve housing can be used for both the diaphragm sensing mechanism 580 and the piston sensing mechanism 980. In addition, a gasket seal 981 can be provided between the valve body housing block 115 and the piston adapter block 983.

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

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

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

[0061] The amount of spring force applied to the sensing mechanism bearing member 1182 via the spring bearing plate 1154 can be adjusted by adjusting the force adjustment plate 1153 (for example, by raising or lowering it). Many different spring adjustment mechanisms can be used, but in the illustrated example, a knob handle 1155 is assembled with the spring housing 1151 and secured by a threaded stem 1156 so that the handle and threaded stem are rotatable to drive the rotatably fixed force adjustment plate 1153 up and down to adjust the compression of the spring 1152. The force adjustment plate 1153 is rotatably fixed by a set screw 1157 (or other suitable projection) on the plate, which rides into a vertical slot 1158 in the spring housing 1151, and the slot is made to provide desired upper and lower limits for the force adjustment plate. A cover panel 1159 may be installed in the slot 1158, for example, to block out debris, moisture, or other contaminants.

[0062] For example, the diaphragm-sensing dome load configuration used to allow the pressure setting of the regulator to be remotely adjustable can be adapted for use with modular diaphragm-sensing pressure reducing valve configurations and back pressure regulating valve configurations.

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

[0064] For example, the piston-sensing dome load configuration used to allow the pressure setting of the regulator to be remotely adjustable can be adapted for use with modular piston-sensing pressure reducing valve configurations and back pressure regulating valve configurations.

[0065] In the embodiment shown in Figure 15, the dome load mechanism 1350 includes upper and lower dome housing shell members 1351-1, 1351-2 assembled with a valve body (e.g., by mounting screws) to define a dome chamber 1352, and a dome load diaphragm 1359 having an outer circumference trapped between the upper and lower shell members, wherein a diaphragm screw 1354 is screwed through a central opening in the dome load diaphragm and positioned to engage with the upper end 1386 of a sensing element bearing member 1382 (e.g., piston members 982, 1082 in Figures 11-12). In the illustrated example, the diaphragm is further supported when support plates 1355-1, 1355-2 are secured to the diaphragm screw 1354 above and below the dome load diaphragm 1359 by nuts 1356. The upper dome housing shell member 1351-1 includes a pressurizing port 1353, which supplies pressurized fluid at a set pressure (e.g., from a secondary pressure regulator) to the dome chamber, applying a corresponding load force to the dome load diaphragm 1359, thereby moving the diaphragm screw 1354 relative to the piston member 1382 of the piston sensing mechanism 1380 (e.g., the pressure regulator piston sensing mechanism 980 in Figure 11, or the back pressure regulator diaphragm sensing mechanism 1080 in Figure 12).

[0066] A pressure regulator may be provided with a self-venting feature, which may be configured to reduce the outlet pressure in the pressure regulator when the regulator's setpoint decreases and the flow through the regulator ceases. The self-venting feature may include a vent passage through a sensing element (e.g., a diaphragm screw in a diaphragm sensing element, or a piston member in a piston sensing element) and a vent passage through the regulator valve body. According to one aspect of this disclosure, a vent adapter block or plate can be assembled with the regulator valve body in combination with the use of a vent sensing element to provide this self-venting feature.

[0067] In the embodiment shown in Figure 16, the vent diaphragm sensing mechanism 1480 includes a flat, flexible disc material (e.g., an elastomer, plastic, or metal suitable for the system fluid) forming a diaphragm 1481, the diaphragm having an outer circumference that is clamped or fixed by a screw configuration between the opposing surface of the valve body housing block 1415 and the opposing surface of the vent adapter block 1490 mounted between the valve body housing block and the load mechanism housing 1451 (e.g., a spring housing or dome housing). As shown in the figure, the vent diaphragm sensing mechanism 1480 may include a vent diaphragm screw 1482 threaded through a central opening in the diaphragm 1481, which includes a vent passage 1482-1 extending from the lower end face of the diaphragm to the middle of the diaphragm screw, which is aligned with a cavity 1491 in the vent adapter block 1490 and is in fluid communication with a vent port 1492 of the vent adapter block 1490. The vent port 1492 may be threaded to connect to a channel for containment and / or analysis of the vent fluid. The vent diaphragm screw 1482 may include a relief valve seat 1482-2 made of plastic (e.g., PEEK) to facilitate sealed engagement with the upper poppet stem 141 at pressures below the regulator setpoint.

[0068] In the embodiment shown in Figure 17, the vent piston sensing mechanism 1580 includes a piston member 1582 that is received in a central piston hole 1584 of a piston adapter block or plate 1583, the upper part of which is received through a central hole in a vent adapter block 1590. The piston adapter plate 1583 and the vent adapter block 1590 together are fixed between the valve body housing block 1515 and the load mechanism housing 1551 (e.g., a spring housing or dome housing) by, for example, a screw configuration. As shown, the vent piston sensing mechanism 1580 may include a vent piston member 1582 that is installed to have a vent passage 1582-1 extending from the lower end face of the piston member to the middle part of the piston member, the vent passage being aligned with a cavity 1591 in the vent adapter block 1590 and in fluid communication with a vent port 1592 in the vent adapter block. The vent port 1592 may be threaded for connection to a channel for containment and / or analysis of the vent fluid. The vent diaphragm thread 1582 may include a relief valve seat 1582-2 made of plastic (e.g., PEEK) to facilitate a sealed engagement with the upper poppet stem 141 at pressures below the regulator setpoint.

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

[0070] Figures 18 to 20 show an exemplary piston-sensing, self-venting, spring-load pressure regulator assembly 2000-1, which includes a valve module 2100 having a valve housing block 2110 and a plug 2120 for holding or housing the configuration of a pressure-reducing poppet 2130 and a valve seat 2140; a piston module 2200 having a piston adapter block 2210 for holding or housing a piston-sensing member 2220 engaged with the poppet; a self-venting module 2300 having a vent adapter block 2310 for defining a vent port 2311 that is in fluid communication with a vent passage 2221 in the piston-sensing member; and a spring-load module 2400 having a load block 2410 for holding a spring-load mechanism (e.g., the spring-load mechanism shown in Figure 13 and described above). The modular assembly blocks 2100, 2200, 2300, and 2400 are provided with holes 2109, 2209, 2309, and 2409 (for example, spaced apart around the outer periphery as shown in the figure) that are aligned to receive elongated bolts 2009 that fasten the blocks together as a single assembly.

[0071] To accommodate different modular configurations in which either or both of the piston module 2200 and the self-vent module are excluded, a uniform mating / sealing configuration may be provided between the stacked module blocks 2110, 2210, 2310, and 2410. Therefore, the regulator assembly may be modified or provided as follows: As shown in Figure 21, the piston module 2200 is omitted, and the valve housing block 2110 is assembled directly to the vent adapter block 2310, resulting in a diaphragm-sensing vent assembly 2000-2 (in which the diaphragm sub-assembly 2250 is installed in a cavity defined between the valve housing block and the vent adapter block). As shown in Figure 22, the piston sensing non-vented assembly 2000-3 is constructed by omitting the vent module 2300 and directly assembling the piston adapter block 2210 to the load block 2410, or As shown in Figure 23, both the piston module 2200 and the vent module 2300 are omitted, and the valve body housing block 2110 is assembled directly to the load block 2410, resulting in a diaphragm-sensing non-vent assembly 2000-4 (in which the diaphragm sub-assembly 2250 is installed in a cavity defined between the valve body housing block and the vent adapter block).

[0072] For uniform fitting and sealing engagement between adjacent blocks, various uniform first and second block assembly interfaces can be used. In an exemplary embodiment, as shown in Figure 19, the valve housing block 2110, the piston adapter block 2210, and the vent adapter block 2310 are each provided with a first assembly interface including uniformly sized upper trepan seal grooves 2115, 2215, 2315 recessed from the upper end face recess 2114 or grooves 2214, 2314 to accommodate annular gasket seals 2106, 2206, 2306. The piston adapter block 2210, the vent adapter block 2310, and the load block 2410 each include a corresponding second assembly interface, which includes a uniformly sized lower annular shoulder 2217 or rib 2317, 2417 that is received into a corresponding counterbore 2114 or groove 2214, 2314 and seals and compresses the annular gasket seals 2106, 2206, 2306.

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

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

[0075] Referring to Figure 23, the exemplary pressure regulator valve body module 2100 is housed in an enlarged upper recess 2118 of the valve body housing block 2110 and includes a guide ring 2170 (e.g., similar to the guide ring 170 described above) that tightly receives the upper poppet stem of the pressure regulator poppet 2130. To modify the regulator assembly as a back pressure regulator assembly 2000-4a or otherwise provide it as shown in Figure 24, the guide ring 2170 may be removed, thereby allowing the enlarged upper recess 2118 of the valve body housing block 2110 to accommodate a larger upper poppet stem of the back pressure poppet 2130a, which is installed in combination with the back pressure valve seat 2140a and the diaphragm back pressure portion assembly 2250a.

[0076] As shown, the module regulator assemblies in Figures 18 to 24 may include components and features that are more fully described in the above description of embodiments in Figures 3 to 17.

[0077] Aspects of the present invention have been described with reference to exemplary embodiments. Modifications and changes will be recalled to others by reading and understanding this specification. This specification is intended to include all such modifications and changes, insofar as they fall within the scope of the appended claims or their equivalents.

Claims

1. A valve assembly, It is a valve body, A main housing defining a first end port, a second end port, and a central cavity, wherein the central cavity extends from the lower end to the upper end of the main housing, The main body plug is assembled with the central cavity of the main body housing and defines a flow path between the first end port and the second end port, The valve body includes, A valve seat carrier subassembly is disposed within the main body housing and fixed between the end face of the main body plug and the counterbore in the central cavity of the main body, wherein the valve seat carrier subassembly comprises a first ring component and a second ring component assembled on an O-ring seal, and the valve seat sealing portion of the O-ring seal is exposed within the inner diameter gap between the inner edges of the first ring component and the second ring component to define the valve seat seal, A poppet assembled with the valve body, which is axially movable within the central cavity of the main housing between a closed position and an open position, wherein in the closed position, the radially extending sealing surface of the poppet seals against the valve seat seal, preventing fluid from flowing through the axial extension of the flow path, and in the open position, the poppet sealing surface of the poppet separates axially from the valve seat seal, allowing fluid to flow between the first end port and the second end port, A valve assembly comprising, A valve assembly in which the first ring component and the second ring component are axially compressible relative to the O-ring seal so as to crush the valve seat sealing portion of the O-ring seal by passing it through the inner diameter gap between the first ring component and the second ring component.

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

3. The valve assembly according to claim 2, wherein the inner counterbore and the outer counterbore form a stepped configuration in the radial direction.

4. The valve assembly according to claim 2, wherein the outer circumference of the second ring component comprises the radially outermost part of the second ring component, and the outer circumference is received within the outer recess.

5. The valve assembly according to claim 1, wherein the valve seat carrier portion assembly is fixed between the upper end face of the main body plug and the counterbore of the main body.

6. The valve assembly according to claim 5, wherein the valve seat carrier subassembly includes a gasket seal that is tightly engaged with the main body recess.

7. The valve assembly according to claim 1, further comprising an actuator assembled with the valve body for moving the poppet between the open position and the closed position.

8. The valve assembly according to claim 7, wherein the actuator includes a load mechanism configured to bias the poppet toward one of the open position and the closed position, and a sensing mechanism configured to fluidly communicate with the first end port and move relative to the load mechanism when the flow pressure in the first end port exceeds a set pressure, thereby enabling the poppet to move toward the other of the open position and the closed position.

9. The valve assembly according to claim 1, wherein the poppet sealing surface is an upward-facing sealing surface.

10. The valve assembly according to claim 1, wherein the poppet sealing surface is a downward-facing sealing surface.

11. A valve seat carrier subassembly for a valve, comprising a first ring component and a second ring component assembled on an O-ring seal, wherein the valve seat seal portion of the O-ring seal is exposed within the inner diameter gap between the inner edges of the first ring component and the second ring component to define the valve seat seal, The first ring component and the second ring component are a valve seat carrier assembly that is compressible in the axial direction relative to the O-ring seal so as to pass the valve seat sealing portion of the O-ring seal through the inner diameter gap between the first ring component and the second ring component and crush it.

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

13. The valve seat seal is located opposite the first side of the valve seat carrier assembly according to claim 11.

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

15. The valve seat carrier assembly according to claim 13, further comprising a face seal O-ring disposed in an annular groove within the second side portion of the valve seat carrier assembly, wherein the second side portion is on the opposite side of the first side portion.

16. A valve seat carrier subassembly for a valve, comprising a first ring component and a second ring component assembled on an O-ring seal, wherein the valve seat seal portion of the O-ring seal is exposed within the inner diameter gap between the inner edges of the first ring component and the second ring component to define the valve seat seal, A valve seat carrier subassembly comprising: the first ring component comprising a flange extending radially inward defining an inner counterbore and a flange extending axially upward defining an outer counterbore; and the second ring component comprising an outer periphery seated within the outer counterbore of the first ring component and a flange extending axially downward extending toward the radially inward flange of the first ring component, defining an annular cavity for the O-ring seal and the inner diameter gap.

17. The valve seat carrier partial assembly according to claim 16, wherein the inner counterbore and the outer counterbore form a stepped configuration in the radial direction.

18. The valve seat carrier subassembly according to claim 16, wherein the outer periphery of the second ring component comprises the radially outermost part of the second ring component, and the outer periphery is received within the outer counterbore.

19. The valve seat carrier assembly according to claim 16, wherein the first ring component and the second ring component are compressible in the axial direction relative to the O-ring seal so as to pass the valve seat sealing portion of the O-ring seal through the inner diameter gap between the first ring component and the second ring component and crush it.

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