In-line Pressure Regulator Nested Inside Single-Stage Housing
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Solution Overview
Problem
In-line pressure regulators require additional space and system length, increasing installation challenges in space-constrained environments, and their external positioning leads to higher weight, component count, and manufacturing costs.
Innovation Solution
The development of an in-line pressure regulator that can be positioned entirely inside the inlet port of another regulator, eliminating the need for a housing and allowing for a two-stage pressure reduction configuration within the same face-to-face dimensions, reducing installation time and costs by integrating a piston assembly that slidably engages the inlet port surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an in-line pressure regulator is externally positioned relative to the single-stage regulator, then the decaying inlet effect is reduced, but the space requirement and system length increase
Solution Approach 1:
The in-line regulator and single-stage regulator are merged into a single integrated device, combining the first stage pressure reduction mechanism and second stage pressure reduction mechanism within one housing. This eliminates the need for separate external positioning while maintaining both regulatory functions, thereby reducing system length while preserving the decaying inlet effect reduction benefit
Solution Approach 2:
The in-line regulator components are nested within the housing of the single-stage regulator, with the piston assembly and inlet seat positioned internally. This nesting arrangement allows the first stage pressure reduction to occur within the same spatial envelope as the second stage, reducing overall system length while maintaining functional separation
2Reliability
If an in-line pressure regulator is externally positioned, then pressure control is improved, but the weight and component count increase
Solution Approach 1:
The housing structures of the in-line regulator and single-stage regulator are merged into a single unified housing, eliminating duplicate structural components. This consolidation reduces the total weight while maintaining both pressure control functions, as the single housing provides structural support for both the inlet seat and outlet seat assemblies
Solution Approach 2:
The single housing serves multiple functions: it contains the first stage pressure reduction mechanism, supports the inlet seat, contains the second stage pressure reduction mechanism, and provides the external connection interfaces. This multi-functionality reduces the need for separate structural components, thereby reducing overall weight
3Adaptability or versatility
If an in-line pressure regulator is externally positioned, then installation flexibility is maintained, but installation time and cost increase
Solution Approach 1:
The in-line regulator and single-stage regulator are merged into a single replaceable unit with external connection interfaces. This allows the entire two-stage pressure reduction system to be installed as one module, reducing installation time while maintaining the flexibility to replace or reposition the complete assembly. The unified housing provides standard external connections for upstream and downstream piping
Solution Approach 2:
The in-line regulator is pre-assembled and configured within the unified housing before installation. The piston assembly, inlet seat, and outlet seat are pre-positioned and sealed, allowing for quick installation without requiring separate assembly steps on-site. This preliminary configuration reduces installation time while maintaining adaptability through standardized external interfaces
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
This solution reduces the decaying inlet effect, provides greater control over outlet pressure settings, decreases overall weight and component count, and minimizes installation time and costs by eliminating the need for piping re-routing and housing, while maintaining the same face-to-face dimensions as single-stage regulators.
Implementation Method 1
The piston assembly is to slidably and sealingly engage a surface of the inlet port
Data Source
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AI summary
In-line pressure regulators are described. An example in-line pressure regulator includes a body having threads to threadingly engage a port of another pressure regulator. The body defines an inlet, an aperture, and a seating surface. Additionally, the example in-line pressure regulator includes a piston assembly operatively coupled to a valve plug. The piston assembly is slidably movable relative to the body to move the valve plug relative to the aperture and the seating surface to control a flow of fluid between the inlet and the other regulator. Additionally, the piston assembly is to slidably and sealingly engage a surface of the port of the other pressure regulator.