Abstract:
A pressure regulator having a conduit with a plurality of adjustable valves inserted reversibly into the conduit. The valves are aligned along the axis of water flow. The interior of the conduit is divided into an inlet chamber and outlet chamber by a septum. The valves are inserted into the inlet chamber, and valve seats protrude through holes in the septum into the outlet chamber, thereby sealing the inlet chamber from the outlet chamber. Fluid flows into the conduit, into the inlet chamber, through the open valve, into the outlet chamber, and then flows out of the conduit. The valves regulate fluid pressure in the outlet chamber. The degree of pressure regulation can be adjusted for each valve by turning pressure adjustment knobs on the top of the valves to produce precise regulation of pressure and fluid flow. A conduit plug can replace a valve in the conduit.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims priority to U.S. Provisional Patent Application No. 61/186,522, filed Jun. 12, 2009, the disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to pressure regulators for fluids and, more particularly, to a pressure regulator that has a plurality of adjustable pressure and flow control valves with diaphragm chambers, the valves being positioned in a conduit having an inlet chamber and an outlet chamber. 
     BACKGROUND OF THE INVENTION 
     In many fluid delivery systems overpressure protection is needed to prevent damage to pipes, conduits, vessels, and the like that may result from excessive fluid pressures. In some cases is it desirable to have a plurality of pressure regulating valves in parallel or in series in order to convey the required flow capacity with reasonably accurate pressure regulation, but this type of system may be complex, expensive and difficult to install and maintain. 
     What is needed is a single, easy to install, pressure regulator that will provide for a high flow rate yet allow precise regulation of fluid pressure with simple variable pressure control devices that are modular and thus easy to replace. 
     SUMMARY OF THE INVENTION 
     The present invention is a fluid pressure regulator having a conduit with an inlet port, an outlet port, and an internal septum dividing the interior of the conduit into an inlet chamber and an outlet chamber. The inlet port opens only into the inlet chamber and the outlet port opens only into the outlet chamber. The conduit has two or more conduit openings for the reversible insertion of valves or valve cartridges, and the septum has two or more septum openings for reversible insertion of valves. The valves seal the inlet chamber from the outlet chamber when they are placed within the conduit. The valve cartridge has a spring, a seat disc, and a valve seat. The spring exerts a pushing force to push the seat disc away from the valve seat to open the valve. 
     The valve has a diaphragm creating a diaphragm chamber in communication with the outlet chamber and with the fluid and pressure therein. The valve has a piston which isolates the diaphragm chamber from the inlet chamber and the fluid and pressure therein. The diaphragm pushes against the spring when pressure in the outlet chamber exceeds the pushing force of the spring, thereby causing the seat disc to be pulled into the valve seat to close the valve. The seat disc and the valve seat are positioned within the outlet chamber. The diaphragm chamber is connected to an outlet pressure sensing port which is in contact with fluid and pressure in the outlet chamber. 
     The valve has a pressure adjustment knob at a top end of the valve, a pressure adjustment screw, and a numeric pressure indicating disc. The pressure adjustment knob is rotatable clockwise or counterclockwise to adjust the degree of tension in the spring by compressing or decompressing the spring. The greater the tension in the spring the greater the fluid pressure required to move the seat disc into the valve seat to close the valve to disrupt the flow of water through the valve. 
     By adjusting the pressure adjustment knobs the pressure drop from the inlet port to the outlet port can be adjusted very precisely and accurately. When maintenance is required, one or more of the valve cartridges can be removed from the conduit without removing the conduit from the pipes or tubing to which it is connected at the inlet port and at the outlet port. 
     An advantage of the present invention is flow capacity enhanced though specific alignment of the valve cartridges. 
     Another advantage is flow control accuracy through independent pressure adjustment of a plurality of valve cartridges. 
     Another advantage is flow capacity expandability by the use of valve cartridge plugs which can be fitted in place of valve cartridges to limit flow and allow for future flow expandability. 
     Another advantage is the use of multiple valve cartridges which allows for each valve to be adjusted to regulate pressure independently and open or close sequentially, dependent upon the immediate flow requirement. 
     Another advantage is that the independently adjustable valve cartridges allow the pressure regulator to control the flow of water with a high level of precision, offering superior durability with little required maintenance. 
     Another advantage is that variations in inlet pressure do not affect regulated outlet pressure as long as inlet pressure remains greater than the set pressure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows an illustration of the multi-cartridge pressure regulator of the present invention. 
         FIG. 2  shows the conduit of the pressure regulator with the valve cartridges removed. 
         FIG. 3  shows a bisected view of the conduit further showing the internal septum within the conduit, dividing the conduit into an inlet chamber and an outlet chamber. 
         FIG. 4  illustrates a typical valve system or cartridge that may be used with the pressure regulator of the present invention. 
         FIG. 5  shows a side cross-sectional view of the multi-valve pressure regulator of the present invention. 
         FIG. 6  shows an end view of the pressure regulator from the inlet end. 
         FIG. 7  shows an end view of the pressure regulator from the outlet end. 
         FIG. 8  shows a side cross-sectional view of the pressure regulator in which one of the valve cartridges has been replaced with a cartridge plug. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the following description details the preferred embodiments of the present invention, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of the parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced in various ways. 
       FIG. 1  shows an illustration of the multi-cartridge pressure regulator  10  of the present invention. The pressure regulator  10  has a conduit  11  and has three valves or valve cartridges  12  on top of conduit  11  wherein the valve cartridges  12  are aligned, preferably, sequentially and in series along the axis of fluid flow. This alignment of the valve cartridges  12  allows for greatest flow of water through the pressure regulator  10 . Each valve cartridge  12  has a pressure adjustment knob  13 . Conduit  11  has three openings with threaded bases  14  for reversible attachment of the valve cartridges  12 . These openings are also aligned, preferably, sequentially and in series along the axis of fluid flow. This alignment of the openings and valve cartridges  12  allows for the greatest flow through the conduit  11 . The valve cartridges  12  are attached to the threaded bases  14  by means of threaded nut  15 . Conduit  11  has an inlet port  16  on one end.  FIG. 2  shows the conduit  11  with valve cartridges  12  removed.  FIG. 3  shows a bisected view of conduit  11  further showing an outlet port  20 . The internal portion of conduit  11  has an internal septum  17  which divides the internal portion of conduit  11  into an upper (or inlet) chamber  18  and into a lower (or outlet) chamber  19 . The inlet port  16  opens only into the inlet chamber  18  and the outlet port  20  opens only into the outlet chamber  19 . Septum  17  has three holes or openings  22 . 
       FIG. 4  illustrates a typical valve system or cartridge  12  that may be used with the pressure regulator  10  of the present invention. Valve cartridge  12  has a pressure adjustment knob  13  at the top and a valve seat  23  at the bottom. Valve seat  23  includes a seat disc  41  and a seat shell  42 . Valve  12  further has a numeric pressure indicating disc  26 , a pressure adjustment screw  27 , a spring button  28 , a spring chamber  29 , a pressure spring  30 , a pressure plate  31 , a diaphragm  32 , a piston  33 , a u-cup seal  34 , a strainer screen  35 , a retainer  36 , a body seat or insert  37 , an outlet pressure sensing port  38 , an o-ring  39 , and a pull rod  40 . There is a diaphragm chamber  21  between the piston  33  and the diaphragm  32 . The pressure plate  31 , diaphragm  32 , piston  33 , u-cup seal  34  and retainer  36  are secured to the upper end of the pull rod  40  by way of threaded nut  43 . The seat disc  41  is secured to the lower end of pull rod  40  by way of threaded seat shell  42 . When all parts are secured to the pull rod  40 , they combine to form a pull rod sub-assembly that functions in a cohesive manner. 
       FIG. 5  shows a side cross-sectional view of the pressure regulator  10 .  FIG. 6  shows an end view of the pressure regulator  10  from the inlet end  16 , and  FIG. 7  shows an end view of the pressure regulator  10  from the outlet end  20 . Spring  30  pushes down on the pressure plate  31  which is connected to the piston  33 . When piston  33 , attached to the upper end of pull rod  40 , is pushed down the pull rod  40  is pushed down, and the seat disc  41  is pushed down, away from the valve seat  23 , which opens valve  12 . The diaphragm  32  is between the pressure plate  31  and the piston  33 . The diaphragm  32  creates the diaphragm chamber  21  around the piston  33 . The diaphragm chamber  21  is in communication with the outlet sensing port  38  which is open to the outlet chamber  19  and to the fluid and pressure therein. If the pressure in outlet chamber  19  is greater than the force of spring  30  pushing on pressure plate  31 , then that pressure pushes upon diaphragm  32 , upon pressure plate  31 , and upon spring  30 , thereby pulling up on pull rod  40  and pulling seat disc  41  into valve seat  23 , which closes valve  12 . 
     Water pressure at the inlet  16  will cause water to flow into inlet chamber  18 , then through strainer screens  35  and pass the valve seat  23 , thereby filling the outlet chamber  19  and filling the diaphragm chamber  21  through the outlet pressure sensing ports  38 . The water will continue to flow until pressure increases sufficiently to cause the diaphragm  32  to oppose the downward force from the pressure spring  30  and lift the seat disc  41  into the valve seat  23  by way of the pull rod  40  and pull rod sub-assembly. The valve cartridges  12  are placed into the threaded bases  14 , and the valve seats  23  project through the septum openings  22 . As threaded nut  15  is screwed into the threaded base  14  the valve cartridges  12  are sealed in the threaded bases  14  and the valve seats  23  are sealed in the septum  17 . The inlet chamber  18  is thus sealed from the outlet chamber  19 . The valve seats  23  and seat discs  41  are positioned within the outlet chamber  19 , and the pressure sensing ports  38  are in contact with the fluid and fluid pressure in the outlet chamber  19 . 
     The pressure adjustment knobs  13  can be rotated clockwise or counter clockwise to adjust the degree of tension in the pressure spring  30  by compressing or decompressing the spring  30 . The greater the tension in pressure spring  30  the greater the pressure the water must have to move the seat disc  41  into the valve seat  23  to disrupt the flow of water through the valve  12 . Thus, the greater the tension in pressure spring  30  the greater the pressure in the outlet chamber  19 . By adjusting the pressure adjustment knobs  13  the pressure drop from the inlet port  16  to the outlet port  20  can be adjusted very precisely and accurately. When maintenance is required, one or more of the valve cartridges  12  can be removed from the threaded base  14  by unscrewing the threaded nut  15 , without removing the conduit  11  from the pipes or tubing to which it is connected at the inlet port  16  and at the outlet port  20 . 
     The purpose of the valve cartridges  12  is to regulate and reduce pressure on the outlet side  20  of the conduit  11 . When a pressure regulator  10  of the present invention is initially installed and commissioned it is normally in the full open position allowing water to flow through the device uninterrupted. The valve  12  is held in the full open position by the pressure spring  30 . Pressure rises when the system is filled. This rise in pressure results in an increase in the upward force against the diaphragm  32  which may eventually exceed the downward force from the pressure spring  30  causing the valve  12  to close. When a tap is opened downstream, a reduction in outlet pressure is produced. This pressure reduction effectively decreases the force against the diaphragm  32  and the pressure spring  30  takes over again causing the valve  12  to open until demand for water is satisfied. Key components of the valve cartridge  12  include the diaphragm  32  and pressure spring  30 . The piston  33 , along with the u-cup seal  34 , serve only to isolate the diaphragm chamber  21  from the inlet chamber  18  and the fluid and pressure therein, and do not directly cause the valve  12  to open or close. The use of multiple valve cartridges  12  allows for each to be adjusted to regulate pressure independently and open or close sequentially, depending upon the immediate flow requirement. The plurality of independently adjustable valves allows the overall pressure regulator  10  to control the flow of water with a higher level of precision than conduits fitted with a single valve. In addition, the use of valve cartridges  12  offers great durability with little required maintenance. Variations in inlet pressure do not in any way affect regulated outlet pressure (or set pressure) provided, of course, that inlet pressure remains greater than the set pressure. 
       FIG. 8  shows a side cross-sectional view of the pressure regulator  10  in which one of the valve cartridges  12  has been replaced with a conduit plug (cartridge plug)  45 . One or more of the valve cartridges  12  are replaceable with cartridge plugs  45 , reversibly insertable into the conduit openings. The cartridge plug  45  is secured by means of threaded nut  15  and effectively seals the openings in both the internal and external portions of the conduit  11  by means of o-rings  39 . The maximum flow capability of the pressure regulator  10  can be limited or reduced through the use of the cartridge plug  45  which can be fitted in place of one or more of the valve cartridges  12 . This will allow the regulator  10  to function more effectively when flow requirements are minimal yet allow for expansion as future demand for water increases. 
     The foregoing description has been limited to specific embodiments of this invention. It will be apparent, however, that variations and modifications may be made, by those skilled in the art, to the disclosed embodiments of the invention, with the attainment of some of all of its advantages and without departing from the spirit and scope of the present invention. For example, the pressure regulator can be constructed of metal or plastic or a combination thereof. The pressure regulators can be used in series or in parallel or both in pipes and tubing. One or more valve cartridges can be used in a single pressure regulator. The pressure regulators will regulate both liquid and gas flow. 
     It will be understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated above in order to explain the nature of this invention may be made by those skilled in the art without departing from the principle and scope of the invention as recited in the following claims.