Hybrid Gas Outlet Assembly for Pressure Testing and Flow Control
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Solution Overview
Problem
Existing gas regulators often require separate devices for pressure and flow control, and multi-stage outlet assemblies experience flow restrictions during pressure testing, limiting flexibility and efficiency.
Innovation Solution
A hybrid pressure and flow regulation system with an outlet assembly featuring a housing, orifices, and internal mechanisms that automatically adjust flow paths based on backpressure to achieve precise pressure and flow rates, including a movable poppet and biasing members for seamless transitions between flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multi-stage outlet assembly is used for hybrid pressure and flow regulation, then both pressure and flow control are achieved with a single apparatus, but flow restrictions occur during pressure testing
Solution Approach 1:
The outlet assembly incorporates a movable poppet that automatically transitions between different positions based on backpressure conditions. At low backpressure, the poppet positions the first orifice to enable precise flow control. At high backpressure during pressure testing, the poppet moves to bypass the first orifice entirely, allowing unrestricted high flow rates. This dynamic adaptation resolves the contradiction between needing flow restriction for precision control and needing high flow for efficient pressure testing.
Solution Approach 2:
The system changes the effective flow path parameters based on operating conditions. The movable poppet alters which orifices are active in the flow path, effectively changing the system's flow characteristics. This parameter change allows the same apparatus to provide both precise flow control (when first orifice is active) and high flow capacity (when bypassing first orifice), resolving the contradiction between adaptability and productivity.
2Reliability
If separate regulators are used for pressure control and flow control, then each function can be optimized independently, but device complexity and operational requirements increase
Solution Approach 1:
The patent merges pressure control and flow control functions into a single outlet assembly with a unified structure. The movable poppet mechanism integrates both control functions, allowing the system to automatically provide pressure-regulated flow at low pressures and high flow capacity at high pressures without requiring separate regulators. This merging reduces device complexity while maintaining the reliability of independent function optimization through the integrated design.
Solution Approach 2:
The outlet assembly is designed as a universal device that performs multiple functions: it provides precise flow control for normal operation and unrestricted high flow for pressure testing. The movable poppet enables the same apparatus to adapt to different operational modes, eliminating the need for separate specialized regulators and reducing overall system complexity while maintaining functional reliability.
3Measurement precision
If the first orifice is always active for precise flow control, then flow regulation precision is improved, but flow rate is limited during pressure testing
Solution Approach 1:
The movable poppet dynamically controls the activation of the first orifice based on backpressure conditions. During normal operation with low backpressure, the poppet maintains the first orifice in the flow path for precise flow control. During pressure testing with high backpressure, the poppet automatically moves to bypass the first orifice, eliminating flow restrictions and enabling high flow rates. This dynamic switching resolves the contradiction between precision control and high productivity.
4Adaptability or versatility
If multiple orifices and auxiliary pathways are included for different flow rates, then adaptability for various operations is improved, but device complexity increases
Solution Approach 1:
Rather than requiring manual switching between multiple fixed configurations, the patent uses a movable poppet that automatically transitions between positions based on backpressure. This dynamic mechanism simplifies the user interface while providing multiple flow control modes: precise control through the first orifice at low pressure, and high flow through auxiliary pathways at high pressure. The automatic adaptation reduces operational complexity despite the multi-functional design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and precise regulation of gas flow and pressure without the need for multiple regulators, ensuring flexibility for various operations like brazing, purging, and pressure testing with clear visual feedback.
Implementation Method 1
internal mechanisms that automatically adjust flow paths based on backpressure
Implementation Method 2
movable poppet and biasing members for seamless transitions between flow rates
Data Source
AI summary
An outlet assembly for hybrid pressure and flow regulation includes a first orifice of a first size, a second orifice of a second size that is larger than the first size, and a mechanism that automatically moves the first orifice between a first position, a second position, and a third position. When the first orifice is in the first position, the flow of gas passes through the first orifice, which regulates a flow rate of the flow of gas through the second orifice. When the first orifice is in the second position, the flow of gas primarily bypasses the first orifice and flows through the second orifice with a first specific flow rate. When the first orifice is in the third position, the flow of gas primarily bypasses the first orifice and flows through the second orifice with a second specific flow rate.