Abstract:
A check valve comprising a valve housing having an input opening and an output opening, a first sealing mechanism disposed in the valve housing, said first sealing mechanism having a valve head coupled with an overmold layer, a second sealing mechanism disposed in the valve housing, said second sealing mechanism having a seal coupled with a seal retainer, and a compression device coupled with the first and second sealing mechanisms, wherein said compression device is configured to exert a force on the first and second sealing mechanisms.

Description:
TECHNICAL FIELD 
       [0001]    The present application relates generally to check valves, and more specifically to check valves used in float equipment. 
       BACKGROUND OF THE INVENTION 
       [0002]    Check valves in float equipment typically use a one-piece valve head “overmold,” where the entire valve head is molded and the seal mechanism is a single piece. These types of seal mechanisms can be damaged during use and the seal mechanism often becomes de-bonded. If damage to the seal is experienced, the valve will not be able to prevent fluid flow. 
       SUMMARY OF THE INVENTION 
       [0003]    A check valve is provided that includes a valve housing having an input opening and an output opening. A first sealing mechanism within the valve housing has a valve head that is coupled to an overmold layer. A compression device coupled to the first sealing mechanism exerts a force on the first sealing mechanism. 
         [0004]    Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0005]    Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which: 
           [0006]      FIG. 1  is a cross section of a check valve in accordance with an exemplary embodiment of the present disclosure; 
           [0007]      FIG. 2  is a cross section of a valve head and overmold layer in accordance with an exemplary embodiment of the present disclosure; 
           [0008]      FIG. 3  is a cross section of a valve seal in accordance with an exemplary embodiment of the present disclosure; 
           [0009]      FIG. 4  is a cross section of a seal retainer in accordance with an exemplary embodiment of the present disclosure; 
           [0010]      FIGS. 5(   a )-( c ) are different views of a spring retainer in accordance with an exemplary embodiment of the present disclosure; 
           [0011]      FIG. 6  is a cross section of a check valve in accordance with an exemplary embodiment of the present disclosure; and 
           [0012]      FIG. 7  is a cross section of a valve head and overmold layer in accordance with an exemplary embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0013]    In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures might not be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness. 
         [0014]      FIG. 1  is a cross section of a check valve  100  in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 1 , check valve  100  includes a valve seat  101  and spring retainer  110  for housing the internal structure of the check valve. Check valve  100  also includes an input opening  102  and an output opening  103  allowing for the flow of concrete, mud, or other fluids in one direction while preventing flow in the reverse direction. Additionally, check value  100  comprises a valve head  104  coupled with overmold layer  105 , a seal  106  coupled to valve head  104  by a seal retainer  107 , a valve stem  108  extending into stem guide  112 , and a spring  109  coupled with a spring retainer  110 . Check valve  100  can be fabricated from a composite material such as phenolic resin, metal including aluminum and phosphorus bronze, rubber, elastic polymer, any other suitable material, or a combination of suitable materials, except for spring  109 , which is metal or other suitable material, capable of sustaining elevated temperatures and high pressures. 
         [0015]    In one exemplary embodiment of the present disclosure, input opening  102  of check valve  100  is sealed by two sealing mechanisms, each capable of providing a high pressure seal independently of one another. In the event that one of the seal mechanisms is damaged or otherwise rendered non-functional, the other seal mechanism can continue to prevent fluid flow. 
         [0016]      FIG. 2  is a cross section of valve head  104  and overmold layer  105  in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 2 , the first sealing mechanism comprises a valve head  104  coupled with an overmold layer  105 . The valve head  104  and overmold layer  105  are configured to form a high pressure seal with input opening  102 . Overmold layer  105  can be formed from rubber, elastic polymer, any other suitable material or a combination of suitable materials to provide a seal with input opening  102 . Overmold layer  105  can be positioned on valve head  104  using overmolding, injection molding, wrapping, or any suitable alternative process. 
         [0017]    Referring again to  FIG. 1 , the second sealing mechanism comprises a seal  106  coupled to valve head  104  and valve stem  108  by a seal retainer  107 . Seal  106  can be formed from rubber, elastic polymer, phenolic resin, aluminum, any other suitable material or a combination of suitable materials that are mechanically coupled to valve head  104  and valve stem  108  by seal retainer  107 . Valve head  104 , seal retainer  107 , and valve stem  108  can be formed from phenolic resin, aluminum, rubber, elastic polymer, any suitable material or a combination of suitable materials. 
         [0018]      FIG. 3  is a cross section of valve seal  106  in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 3 , valve seal  106  can have grooves or depressions that allow for coupling with seal retainer  107 . 
         [0019]      FIG. 4  is a cross section of seal retainer  107  in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 4 , seal retainer  107  can have a structure configured to couple with seal  106 . Additionally, in an exemplary embodiment of the present disclosure, seal retainer  107  can have internal threading allowing for mechanical coupling with valve stem  108 . 
         [0020]    In one exemplary embodiment of the present disclosure, seal retainer  107  and valve head  104  are coupled with valve stem  108  using threading, bonding, or any suitable alternative. The coupling of seal retainer  107  and valve stem  108  establishes the coupling of seal  106  and valve head  104 . By mechanically fastening valve seal  106  to valve head  104  and valve stem  107  using seal retainer  108 , the present disclosure prevents issues associated with valve bonded seals becoming de-bonded as a result of wear and use. 
         [0021]      FIGS. 5(   a )-( c ) are several views of spring retainer  110  in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 5(   a ), spring retainer  110  can have a number of legs  111  configured to support spring  109 . Spring retainer  110  also comprises output opening  103  to allow for the flow of mud, concrete, or other fluid through check valve  100 . In one exemplary embodiment of the present disclosure, spring retainer  110  can be coated or molded to prevent the surface wear normally experienced in valves after several hours of mud, concrete, or other fluid circulation. The coating or molding of spring retainer  110  can be formed from rubber, elastic polymer, phenolic resin, metal such as phosphorus bronze or other suitable alternatives, any other suitable material or a combination of suitable materials for reducing surface wear and sustaining the integrity of check valve  100 . 
         [0022]    In one exemplary embodiment of the present disclosure shown in  FIGS. 5(   b ) and ( c ), spring retainer  110  can have threading  113  to facilitate mechanical coupling to valve seat  101 . In this embodiment, valve seat  101  and spring retainer  110  can be mechanically connected using threading, molding, latching, or any other suitable alternatives. 
         [0023]      FIG. 6  is a cross section of a check valve  600  in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 6 , check valve  600  includes a valve seat  601  and spring retainer  610  for housing the internal structure of the check valve. Check valve  600  also includes an input opening  602  and an output opening  603  allowing for the flow of concrete, mud, or other fluids in one direction while preventing flow in the reverse direction. Additionally, check value  600  comprises a valve head  604  coupled with overmold layer  605 , a valve stem  606  extending into stem guide  608 , and a spring  607  coupled with a spring retainer  610  having a number of legs  609 . As previously discussed, check valve  600  may be a composite material such as phenolic resin, metal including aluminum and phosphorus bronze, rubber, elastic polymer, any other suitable material, or a combination of suitable materials, except for spring  607 , which is metal or other suitable material, capable of sustaining elevated temperatures and high pressures. 
         [0024]    In one exemplary embodiment of the present disclosure, valve head  604  and overmold layer  605  of check valve  600  are configured to form a high pressure seal with input opening  602 . 
         [0025]      FIG. 7  is a cross section of valve head  604  and overmold  605  layer  605 , in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 7 , valve head  604  and overmold layer  605  are configured to form a high pressure seal with input opening  602 . As previously discussed, overmold layer  605  can be formed from rubber, elastic polymer, any other suitable material or a combination of suitable materials to provide a seal with input opening  602 . Overmold layer  605  can be positioned on valve head  604  using overmolding, injection molding, wrapping, or any suitable alternative. Overmold layer  605  can fully or partially encompass valve head  604 . 
         [0026]    In one exemplary embodiment of the present disclosure, valve head  604  is coupled with valve stem  606  using threading, bonding, or any suitable alternative. By mechanically fastening valve head  604  and valve stem  606 , the present disclosure prevents issues associated with valve bonded seals becoming de-bonded as a result of wear and use. 
         [0027]    In another exemplary embodiment of the present disclosure, valve head  604  and overmold layer  605  can be oblong to match the dimensions of input opening  602  and therefore form a more secure seal. 
         [0028]    In yet another exemplary embodiment of the present disclosure, overmold layer  605  can be configured to have a protruding lip  611  configured to interface with valve seat  601 . In this manner, protruding lip  611  of overmold layer  605  prevents the reverse flow of liquids when valve head  604  and overmold layer  605  are engaged with input opening  602 . 
         [0029]    It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.