Abstract:
The present invention provides, in part, a valve assembly and method that maintains balance of flow to pressure in fluid and gas piping system applications. In one embodiment, the present invention includes a main body component adapted to retain a chamber body component, a fluid control plate and seal, and a chamber cap. The chamber body component is slidably maintained within the main body component. A resilient gland member is securably attachable to one end of the main body component and the chamber body component, and acts as a seal and a memory for returning the chamber body component to a standard operating position upon fluid pressure environment shifting the chamber body component towards a shut off position.

Description:
FIELD OF THE INVENTION 
     The present invention relates to fluid flow systems, and more particularly to a check valve assembly that regulates fluid flow rate and enhances stoppage and re-starting of fluid flow in piping systems. 
     BACKGROUND OF THE PRESENT INVENTION 
     Piping systems exist to facilitate the flow of fluids (e.g., liquid, gas (such as air) or plasma). For example, homes, schools, medical facilities, commercial buildings and other occupied structures generally require integrated piping systems so that water and/or other fluids can be circulated for a variety of uses. Liquids and/or gases such as cold and hot water, breathable air, glycol, compressed air, inert gases, natural gases, cleaning chemicals, waste water, plant cooling water and paint and coatings are just some examples of the types of fluids and gases that can be deployed through piping systems. Tubing/piping types can include, for example, copper, stainless steel, CPVC (chlorinated polyvinyl chloride) and PEX (cross-linked polyethylene). For purposes of the present disclosure, the term “pipe” or “piping” will be understood to encompass one or more pipes, tubes, piping elements and/or tubing elements. 
     Piping connections are necessary to join various pieces of pipe and must be versatile in order to adapt to changes of pipe direction, fluid types and fluid flow rates required in particular piping system implementations. For example, fittings and valves may be employed at the ends of open pieces of pipe that enable two pieces of pipe to fit together in a particular configuration. Among fitting types there are elbows, “tees”, couplings adapted for various purposes such as pipe size changes, ends, ball valves, stop valves, check valves and partial angle connectors, for example. 
     Valves have different purposes depending upon the application. Washing machines, heaters, sinks, ice makers and other home and commercial appliances typically operate with fluid flow valves in order to regulate fluid flow operations and prevent damage. For example, if a washing machine hose bursts, it can discharge hundreds of gallons of water in an hour or less, and cause catastrophic damage as a result. A flow check valve or stop valve can be provided on the washing machine and can include a sensor to sense the water flow and automatically shut the water off if a hose bursts, for example. 
     Check valves are provided with two ports—one that allows fluid to enter and one that allows fluid to leave. Check valves operate to allow fluid to flow in one direction only through the valve. Flow check valves operate to monitor and maintain the flow rate of fluid through the valve, regardless of the inbound pressure. In any piping system, maintaining the balance of fluid flow to fluid pressure is paramount. The present invention provides a flow check valve that maintains the balance of fluid flow to fluid pressure in a manner that avoids leaks, flooding and other valve problems in the event of downstream system failure. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention provides, in part, a valve assembly and method that maintains balance of flow to pressure in fluid and gas piping system applications. In one embodiment, the present invention includes a main body component adapted to retain a chamber body component, a fluid control plate and seal, and a chamber cap. The chamber body component is slidably maintained within the main body component. A resilient gland member is securably attachable to one end of the main body component and the chamber body component, and acts as a seal and a memory for returning the chamber body component to a standard operating position upon fluid pressure environment shifting the chamber body component towards a shut off position. 
     As a flow check valve, the present invention is not necessarily concerned with preventing water or fluid from flowing back into the system. In one embodiment, the flow check plate (also known as a restrictor plate) of the present invention is secured to the flood stop control seal, which acts as a valve. The valve is biased in the open position and is set to allow certain flow (e.g., 2.5 gallons per minute) via the restrictor plate. The valve and plate are unaffected by the fluid pressure, but react to variations in the fluid flow. The remainder of the device acts as a regulator in order to maintain the balance of flow to pressure. For example, if pressure goes from 35 psi (pounds per square inch) to 80 psi within the device, the chamber body component (a.k.a., the piston) will be pushed towards the flood stop control seal and the gland member will be stretched. The chamber body front end will eventually engage the flood stop control seal, at which time the overflow ports of the chamber body member will be inside an interior chamber of the device exposed to a positive displacement area formed between the main body component and the chamber body component. Further, the fluid diverted through the overflow ports will stay in this interior chamber and act to retain the piston in the engaged position preventing water flow through or past the valve. When the pressure subsides, the gland member is then strong enough and has sufficient retention connections with the main body component and chamber body component to retract and bring the piston back, allowing fluid flow past the valve and releasing the check. The overflow ports are then re-positioned back in the second portion of the main body chamber exposed to an area between the main body component&#39;s rampart member and the chamber cap. 
     In one embodiment of the present invention, the valve assembly of the present invention can be inserted into existing piping or tubing systems as a retrofit device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded front perspective view of one embodiment of the valve assembly of the present invention. 
         FIG. 2  is an exploded front perspective view of one embodiment of the valve assembly of the present invention, with components shown in cross-section. 
         FIG. 3  is a front cross-sectional view of the chamber body component in accordance with one embodiment of the present invention. 
         FIG. 4  is a top plan view of a cap member in accordance with one embodiment of the present invention. 
         FIG. 5  is a cross-sectional view of the embodiment of the cap member taken along line  5 - 5  of  FIG. 4 . 
         FIG. 6  is a front view in cross-section of one embodiment of the main body member of the present invention. 
         FIG. 7  is a breakout view of encircled portion  7 - 7  of  FIG. 6 . 
         FIG. 8  is a top plan view of a gland member in accordance with one embodiment of the present invention. 
         FIG. 9  is a cross-sectional view of the embodiment of the gland member taken along line  9 - 9  of  FIG. 4 . 
         FIG. 10  is a breakout view of encircled portion  10 - 10  of  FIG. 9 . 
         FIG. 11  is a front perspective view of the cross-section of the valve assembly in accordance with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in  FIGS. 1-11 , the valve assembly  10  of the present invention includes a main body component  15  and a chamber body component  20 . It will be appreciated that the assembly of the present invention is provided so as to be inserted, affixed and/or installed within a piping or tubing component (not shown). 
     The main body component  15  and chamber body component  20  are substantially cylindrical bodies with fluid passageways extending axially therethrough, and these components are axially aligned when engaged in accordance with the present invention. In one embodiment of the present invention, main body component  15  and chamber body component  20  are made of brass. In another embodiment of the present invention, one or both of these components may consist of copper or nylon, or other suitable material for the purposes undertaken in accordance with the present invention. 
     As shown in  FIGS. 2 ,  6  and  7 , the main body component  15  includes an outer wall  22  and an inner wall  24 . Together, the inner wall  24  and outer wall  22  comprise an integrated wall. The outer wall  22  of main body component  15  is capable of securely engaging the inner wall of a piping or tubing component. 
     The outer wall  22  extends from a cap edge portion  26  at a first axial end  28  of the main body component  15  to a grooved edge portion  30  at a second axial end  32  of the main body component  15 . The cap edge  26  is a machined lip extending radially outwardly of the outer wall  22  of the main body component and includes a pipe or tube facing internal face  34 , an outer face  36  and an outer edge  38 . As shown in  FIGS. 6-7 , the grooved edge portion  30  is formed so as to provide a radially outwardly extending retaining edge  40  having a pipe or tube facing external face  42 , an outer edge  44  and an inner face  46 . The grooved edge portion  30  further includes an outer wall  48  and a body portion side wall  50 , such that the body portion side wall  50 , the outer wall  48  and the inner face  46  of the retaining edge  40  form an annular groove  52  extending circumferentially around the main body component  15 . The annular groove  52  receives an exterior lip of a gland member as described hereafter. 
     The inner wall  24  of the main body component  15  includes a radially inwardly extending rampart member  55  having a first side wall  56 , a second side wall  58  and an interior edge  60 . The rampart member  55  assists in providing a channel  51  and a physical resistance structure employed by the chamber body  20  and further assists in establishing a positive displacement area during operation of the present invention as will be described hereinafter. In one embodiment of the present invention, as shown in  FIG. 11 , the rampart member second side wall  58  cooperates with the chamber body member  20  to form a positive displacement cavity  59 . 
     The interior edge  60  is capable of slidingly engaging the chamber body component  20  during operation of the present invention, as described in more detail hereafter. In one embodiment of the present invention, the inner wall  24  includes a tapered surface element  62  at the first axial end  28  of the main body component  15 . As shown in  FIG. 2 , the tapered surface element  62  begins at a taper point  64  extending circumferentially around the inner wall  24  and ends at a position  66  under an interior lip  65  of the cap edge  26 . In this way, the tapered surface element  62  and the cap edge interior lip  65  can engage a fluid control plate as described in more detail hereafter. 
     As shown in  FIGS. 2 and 3 , the chamber body component  20  includes an outer wall  70  and an inner wall  72 , together comprising an integrated wall, with the outer wall  70  capable of slidingly engaging the interior edge  60  of the rampart member  55  of main body component  15 . In this way, the chamber body component  20  is not permitted to veer off its axial course during operation, and space is provided appropriately between the outer wall  70  of the chamber body component  20  on both sides of the rampart member  55  of the main body component to permit fluid flow, as shown in  FIG. 11 . The chamber body component  20  can take the form of a substantially cylindrical body element having a channel or cavity  21  therethrough to permit axial flow of fluids. 
     The chamber body component  20  is also formed to include one or more propulsion ports  75  in order to permit fluid to flow in and out of the cavity of the chamber body component during operation. In one embodiment of the present invention, the propulsion ports  75  are positioned so as to function only upon saturation of the flow area, as will be described in more detail hereafter. The outer wall  70  of the chamber body component  20  extends from a first axial end  76  to a second axial end  78 . The chamber body component  20  is formed to include a chamber body head member  80  extending radially outwardly from the outer wall  70  proximate the first axial end  76  and a gland engaging end  82  extending radially outwardly from the outer wall  70  proximate the second axial end  78 . As shown in the embodiment of  FIG. 3 , the head member  80  extends substantially perpendicularly from the outer wall  70  while the gland engaging end  82  extends as indicated at  83  at an acute angle from the outer wall. It will be appreciated that, while the present invention contemplates other embodiments wherein such extension angles differ from that shown in  FIG. 3 , the angles shown in  FIG. 3  assist in structurally supporting the chamber body component  20  within the overall device of the present invention during operation. As shown in  FIG. 3 , the gland engaging end  82  includes an external body wall  84 , an outer radial wall  86  and an outer axial wall  88 . The outer radial wall  86  includes an inner face  91  and an outer face  92 , and the outer axial wall  88  includes an inner face  93 , an outer face  94  and a radial internal edge  95 . An annular groove  100  is formed by the outer radial wall inner face  91 , the outer axial wall inner face  93  and the first external body wall  84  of the chamber body component  20 . The annular groove  100  receives an interior lip of a gland member as described hereafter. 
     In one embodiment of the present invention, the radius R 1  of the first portion  61  of the main body component chamber that houses the chamber body head member  80  is greater than the radius R 2  of the second portion  63  of the main body component chamber. This arrangement assists in creating the desired fluid pressure differential between that occurring near the fluid outbound area (i.e., the area around where plate  170  is located) and that occurring near the fluid inbound area (i.e., from the area where gland  130  is located). Additionally, in one embodiment of the present invention, the chamber body head member  80  has a radius R 4  that is slightly less than the radius R 1  of the first portion  61  of the main body component chamber, and the chamber body component  20  radius R 5  (to outer wall  70 , shown in  FIG. 3 ) is slightly less than the internal radius R 3  of the rampart member  55  within main body component  15 . In one embodiment, the relationship of the respective radii can be such that the chamber body head member radius R 4  is from 0.002 to 0.015 inches less than the radius R 1  of the first portion  61  of the main body component chamber, inclusive, and chamber body component radius R 5  is similarly from 0.002 to 0.015 inches less than the radius R 3  of the rampart member  55 . At the 0.002 inch difference, the maximum amount of tolerable friction occurs. If the distance exceeds the 0.015 inch difference, the chamber body head member  80  and component  20  may not slide evenly within the main body component chamber  61  and within the area encircled by the rampart member  55 , respectively. As such, there may not be enough balancing pressure or back pressure to support proper operation of the components of the present invention. 
     As shown in  FIGS. 2 and 3 , the annular groove  52  within the main body component  15  faces radially outwardly while the annular groove  100  within the chamber body component  20  faces radially inwardly. This arrangement permits the present device to securely engage the gland member described below while maintaining substantially coaxial and parallel alignment of the main body component and chamber body component. Such an arrangement and positioning assists the present device during operation such that fluids and gases do not escape or infiltrate the present invention components as an unintended consequence. 
     As shown in  FIGS. 1-5 , the inner wall  72  of the chamber body component  20  is provided with a thread  110  proximate the second axial end  78  for receiving an end cap  115  as described hereafter. The inner wall  72  further extends through the chamber body head member  80 , extending radially inwardly to form an interior ring  120  having a first side wall  122 , a second side wall  124  and a radially inward edge  126 . A bevel wall  128  extends from the inner wall  72  at a position adjacent the first side wall  122  of the interior ring  120 , and the bevel wall  128  is angled so as to cooperatively engage a control seal during operation of the present invention, as described hereafter. 
     The gland member  130  of the present invention is shown in  FIGS. 1-2  and  8 - 10 . As shown therein, the gland member  130  comprises a unitary, substantially rigid yet somewhat flexible element that acts as both a sealing member and a spring or pressure-balancing member for the device of the present invention. The gland member  130  is a hollow, ring-shaped device having a radially outer wall  132 , a radially inner wall  134  and an exterior wall  136 . The gland member  130  further is formed with an interior face  138  having a substantially C-shaped cross-section with exterior  140  and interior  142  lip elements. As shown in  FIG. 10 , the exterior lip  140  includes a front wall  150 , a radially inward wall  152  and an interior wall  154 , and the interior lip  142  includes a front wall  160 , a radially inward wall  162  and an interior wall  164 . Further, each of the gland member exterior wall  136 , radially outer wall  132  and radially inner wall  134  includes a respective inner surface  144 ,  145 ,  146 , whereby the respective inner surfaces  144 ,  145 ,  146  and the lip members  140 ,  142  cooperatively engage the annular grooves  52 ,  100  of the main body component  15  and the chamber body component  20 , respectively. 
     In one embodiment of the present invention, as shown in  FIG. 10 , the front wall  150  of the exterior lip  140  extends further outwardly than the front wall  160  of the interior lip  142 , and the interior wall  154  of the exterior lip  140  extends further inwardly than the interior wall  165  of the interior lip  142 . Such an arrangement provides the exterior lip  140  with greater surface area and thereby greater strength of connection with main body component than the interior lip  142  enjoys with the chamber body component  20 . Further, as shown in the embodiment of the present invention shown in  FIG. 10 , the radially outer wall  132  of the gland member is thicker in width and shorter in length than the radially inner wall  134 . As a result, the interior lip  142  has a modest amount of additional flexibility to thereby operate as intended, by permitting the chamber body component  20  to move axially within the main body component chamber. In one embodiment of the present invention, as shown in  FIG. 9 , the length L 1  of the radially inner wall  132  can range from approximately 125% to approximately 167% the length L 2  of the radially outer wall  134 , and the width W 1  of the radially inner wall  132  can range from approximately 20% to approximately 40% the width W 2  of the radially outer wall  134 . In a further embodiment of the present invention, the width W 3  of the exterior lip radially inward wall  152  is approximately 175% to approximately 300% the width W 4  of the interior lip radially inward wall  162 . 
     As shown in  FIGS. 2 ,  4  and  5 , a chamber cap  115  is provided in the form of a substantially cylindrical-shaped body  205  having a cavity  208  extending axially therethrough with a head portion  210  at one end  212  of the body  205 . The head portion  210  can be of any shape that can be manipulated for clockwise and counter-clockwise rotation, and is shown in  FIG. 4  in a hexagonal shape. The body portion  205  is provided with an external thread  214  for mating with the internal thread  110  of the chamber body component  20 . 
     In one embodiment of the present invention as shown in  FIGS. 1 ,  2  and  11 , a fluid control plate  170  is designed with one or more fluid control plate flow ports  172  to allow fluid to flow therethrough. The fluid control plate  170  can receive a flow restrictor  180  extending through a central axial opening  173  of the plate, and the flow restrictor  180  thereby extends axially inwardly and into the first portion  61  of the cavity of the main body component  15 . In one embodiment of the present invention, the flow restrictor  180  includes a flood stop control seal or plunger seal  182  that assists in sealing the fluid flow during operation of the device, when required. As shown in  FIGS. 1 ,  2  and  11 , the control seal  182  can have a wider flow-facing end  186  tapered to a narrower downstream end  184 . The outer edge  188  of the flow-facing end  186  of the control seal  180  is adapted to mate with the bevel wall  128  of the chamber body component  20  in substantially flush relation during operation if and when the valve is positioned in shut-off position. The flow restrictor  180  includes a neck portion  189  that securely fits within central axial opening  173  of the plate, as shown in  FIGS. 1 and 11 . The edge  175  of the fluid control plate  170  can be considered a stabilizer edge and wall  174  can be considered a snap slope edge in that the fluid control plate can snap into position within the main body component  15  as a result of the tapered surface element  62  in the main body member inner wall  24 , as shown in  FIG. 11 . In one embodiment of the present invention, the fluid control plate  170  and the flow restrictor  180  with flood stop control seal  182  are separate components, with the flow restrictor  180  being insertable and retainable within fluid control plate  170  by pushing downstream end  184  through the central axial opening  173  of the fluid control plate  170 . An upstream central plug element  189  of the flow restrictor  180  is also provided and can assist with restricting fluid flow during operation as the chamber body component  20  is pushed towards the flow restrictor  180 , as the ring extension  124  surpasses and encircles the plug element  189  if fluid flow exceeds allowed rates, as described in connection with the operation of the invention elsewhere herein. In one embodiment of the present invention, the fluid control plate  170  can be formed of a polymeric material such as polyoxymethylene (POM) and the flow restrictor  180  with flood stop control seal  182  can be formed of EPDM rubber (ethylene propylene diene monomer (M-class) rubber) material. Similarly, the gland member  130  described herein can be formed of EPDM rubber, for example, or similar elastomeric material, in accordance with one embodiment of the present invention. 
     With regard to a method of assembly of the valve device of the present invention, the chamber body component  20  is inserted through an opening  190  at the first axial end  28  of the main body component  15 , and the fluid control plate  170  with flow restrictor  180  and flood stop control seal  182  is inserted and secured into the cap portion  26  of the main body component  15 . The gland member  130  is secured to the main body component  15  and the chamber body component  120  such that the external  140  and internal  142  lips of the gland member  130  securely engage the annular grooves  52 ,  100  described above. The chamber cap  115  is then inserted through the gland member  130  such that the external thread  214  on the chamber cap  115  securely engages the internal thread  110  on the chamber body component  20 . 
     In operation, fluid such as water enters from a piping or tubing element (not shown) into the valve assembly  10  of the present invention from the first axial end of the main body component  15 . It will be appreciated that the fluid can be liquid or gas, and will further be appreciated that the specific gravity of the fluid is inconsequential to the operation of the present invention. The fluid enters at a fluid rate measured, for example, in gallons per minute. If the fluid flow maintains the desired rate (e.g., 2.4 gallons per minute), the valve assembly  10  is unaffected and permits free flow through the cavity of the chamber body component  20  and past the flow stop control seal  182  and through the ports  172  in the fluid control plate  170 . If the incoming fluid flow increases, fluid pressure will build up outside of the chamber body component  20  and will extend around the end of the chamber body component (for example, in the areas  250  around the head portion  205  of the chamber cap  115 ) to push the chamber cap  115  towards the fluid control plate end of the assembly. In this process, the chamber body component  20  will come closer to the fluid sealing member  182 , and the gland member  130  will stretch to permit the extension of the chamber body component. Additionally, propulsion ports  75  will move from a position where they permit fluid to evacuate the chamber body member into channels  255  in  FIG. 11  alongside chamber body component  20 , to where they permit fluid to evacuate the chamber body member  20  in the positive displacement cavity  59  and first portion  61  of the chamber of the main body component  15  beyond the rampart member  55  of the main body member  15 . The propulsion ports  75  thus facilitate some evacuation of fluid from the chamber body member  20 , but ultimately allow the fluid to continue building up and pushing the chamber body member  20  towards the fluid control seal  182 , since the positive displacement cavity  59  is relatively small, and the chamber body member will be pushed by fluid within cavity  61  as the fluid pressure builds up against chamber head portion  80 . It will be appreciated that some balancing fluid flow may occur through slender channels  193 ,  195  shown in  FIG. 11 , assisting with back pressure for the device. 
     When the fluid flow is so great that the fluid control seal  182  seals against the seal engaging bevel edge  128  of the chamber body component  20 , no more fluid can exit through the fluid control plate  170 . Once the flow rate is reduced externally (e.g., from the incoming area  250  in  FIG. 11 ), the pressure on the chamber body component  20  is relaxed, and the chamber body component is returned via pressure from the gland member  130  away from the fluid control seal  182 . 
     It will be appreciated that the present invention requires no spring, and no sealing ring or O-ring type device in order to facilitate movement of adjacent components in valve devices. Further, the present invention can be provided in a form factor that is significantly smaller than that of other devices. In one embodiment of the present invention, the length of the device when assembled is no greater than 1.25 inches. It will further be appreciated that the present invention is versatile and can be employed with fluids and gases of various types. In one embodiment, the device of the present invention can be employed in environments where fluid flow rates range up to 150 gallons per minute or more, or where air pressure is 250 pounds per square inch or more. As sealing rings can build up frictional pressure and heat over time, they can wear down. Additionally, an oil or silicon impregnated seal can suffer from lower tolerances to high pressure and heat, or may potentially ignite or explode at higher temperatures and/or pressures. As the present invention does not employ such seals, it can bear higher temperatures, flow rates and pressures accordingly. Further, as the present invention does not employ steel or other metal, such as might be present in a spring, for example, the present invention is further able to bear higher temperatures, flow rates and pressures. 
     The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.