Multi-Stage Pressure Regulator with Rigid Valve Seat
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Solution Overview
Problem
Existing pressure regulators, whether piston-type or diaphragm-type, face issues with contamination, corrosion, and surface imperfections, leading to unreliable pressure regulation, especially when handling high source pressures, as they either fail due to hard valve and seat designs or suffer from permanent deformation with elastomeric seals.
Innovation Solution
A two-stage regulator design that combines the advantages of hard seat and soft elastomeric seals, using a rigid ball or disk as the flow-obstructing component, supported by elastomeric seals, which allows for controlled compression and prevents damage from high pressures, ensuring reliable pressure regulation across a wide range of source pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a hard valve and seat design is used to handle high source pressures, then the regulator can withstand high pressures, but contamination, corrosion, or surface imperfections cause faulty pressure regulation
Solution Approach 1:
The patent applies different material properties to different parts of the valve assembly: the valve body and seat use hard materials (metal-to-metal) to withstand high pressures, while the sealing surfaces use soft elastomeric materials to maintain reliable sealing. This local differentiation of material properties allows each component to perform its specific function optimally without the drawbacks of using a single material type throughout.
2Reliability
If a soft elastomeric seal is used in the valve assembly, then the seal conforms to minor valve imperfections and is less prone to failure from contamination or corrosion, but the high pressures cause permanent deformation and swelling of the seal
Solution Approach 1:
The elastomeric seal is positioned only where sealing is required, while the pressure-bearing structural components remain hard metal. The seal design allows it to be compressed to a predetermined extent by the valve obstructing component, with the rigid seat preventing further compression. This local application of soft sealing material provides sealing reliability without exposing the entire assembly to the deformation issues that would result from using soft materials throughout.
3Reliability
If an elastomeric seal is used to retain high source pressures, then the seal provides good sealing, but explosive decompression causes permanent deformation and defect of the seal
Solution Approach 1:
The rigid seat is positioned beforehand to limit the compression of the elastomeric seal. When explosive decompression occurs, the rigid seat prevents the seal from being suddenly over-compressed or damaged, as the seat physically stops the obstructing component's travel. This pre-positioned structural element cushions the seal against the harmful effects of pressure sudden changes.
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
The two-stage regulator effectively maintains consistent outlet pressure by transferring excess forces to the rigid valve seat, preventing elastomeric seal deformation and ensuring long-term containment of high pressures, even under temperature fluctuations and varying flow rates.
Implementation Method 1
designed to be sealed by at least two elastomeric seals each being supported on a rigid seat. The rigid seat allows only the obstructing component of the valve to compress the elastomeric seal a predetermined amount
Implementation Method 2
A piston-type regulator uses a spring-biased piston in a bore to regulate output pressure with the piston always trying to reside in equilibrium
Implementation Method 3
One side of the piston is biased by a spring force and the other side of the piston is biased by pressurized gas
Implementation Method 4
A diaphragm-type regulator works in a very similar way. Rather than moving a piston in a bore, a diaphragm acts as a flexure, biased on one side typically by a spring
Data Source
Figure 1
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AI summary
A multi-stage fluid pressure regulator, including a first stage valve arranged to open and close a fluid flow path to control flow of fluid through the valve, a first stage piston arranged for movement to open and close the first stage valve, the piston having an inner side and an outer side, a gas delivery conduit having a proximal end attached to the first stage piston and a distal end extending away from the first stage piston, the gas delivery conduit having a passage in fluid communication with the inner side of the first stage piston, and a second stage valve in fluid communication with the gas delivery conduit, the second stage valve including a second valve chamber into which the distal end of the gas delivery conduit is positioned.