Manifold valve assembly with removable valve seat

A flow control manifold assembly, constructed of a number of manifold valve assemblies. Each manifold valve assembly is formed of first and second valve bodies, each body having at least one inlet port and a plurality of outlet ports. The two valve bodies are connected together in fluid communication with each other. Associated with each valve body is an actuator assembly, which includes a valve actuator and an actuator rod attached to and projecting outward from the actuator, and actuatable by the actuator. In at least one of the valve bodies, a bonnet is affixed to the actuator, and projects into the respective one of the valve bodies. A valve stem, carrying at least one valve plug, is attached to the projecting end of the actuator rod, positioning the valve plug on the opposite side of the bonnet from the actuator. The bonnet includes a valve seat for engagement with the valve plug when the valve plug is actuated to a predetermined position by the actuator. One embodiment provides a third valve body, also in fluid communication with the first valve body, so that flow from one source to two destinations can be controlled by a single valve assembly. Thus the invention replaces a single, expensive, multiple-actuator valve with a pair of inexpensive single-actuator valves which together are less expensive than the single valve they replace, while still preventing the mixing of different types of fluids.

BACKGROUND OF THE INVENTION 
This invention relates to valves for controlling the flow of fluids, and 
particularly to block-and-bleed valves assembled together to form 
manifolds for controlling the flow of fluids from multiple sources to 
multiple delivery destinations. Certain concerns unique to the sanitary 
industry are discussed. 
It is common in the food packaging industry to have a need to connect a 
number of sources of a fluid, such as different types of milk, to a number 
of different filler machines to fill containers, such as gallons, 
half-gallons, quarts and so on. To date these connections have been 
accomplished in the form of a manifold, including a number of lines from 
the source tanks crossing a number of lines leading to the filler 
machines, with the valves being provided to permit or prevent flow of 
fluid from any selected one or more of the source tanks to any chosen one 
or more of the filler machines. This arrangement creates a need for an 
extremely large number of valves, however. For instance, a single manifold 
connecting ten source tanks to ten filler machines, would use over a 
hundred valves to accomplish the control which is necessary and desired. 
In the past, it has been conventional to use specially designed valves to 
control these manifolds, called block-and-bleed valves, sometimes called 
leak detector valves, with one such valve installed at each manifold 
intersection. Block-and-bleed valves are particularly applicable to the 
sanitary industry, because they permit control of flow of different types 
of fluids through the same valve with double protection against 
intermixing of those fluids. That is, it may be desirable to have 
chocolate milk flowing through one part of the valve and white milk 
through another part, or pasteurized milk through one part and raw milk 
through another part, or clean-in-place solution through one part and milk 
or another food fluid through another part. Clearly it is critical that 
these fluids not be permitted to mix, and regulations require that even 
failure of a single seat or valve plug not permit that mixing. 
The type of valve used in the past functioned generally satisfactorily in 
most instances. Being a single valve, however, it was required to be 
extremely complex and expensive, including multiple, coaxial, 
independently operable actuators and valve plugs. Under certain 
circumstances these valves were subject to substantial leakage and product 
waste, and when they did fail in this manner, while preventing mix of 
different fluids, their maintenance was difficult and expensive. 
This invention relates to improvements to the apparatus described above, 
and to solutions to some of the problems raised or not solved thereby. 
SUMMARY OF THE INVENTION 
The present invention includes a manifold valve assembly, formed of first 
and second valve bodies, each body having at least one inlet port and a 
plurality of outlet ports. The two valve bodies are connected together in 
fluid communication with each other. Associated with each valve body is an 
actuator assembly, which includes a valve actuator and an actuator rod 
attached to and projecting outward from the actuator, and actuatable by 
the actuator. In at least one of the valve bodies a bonnet is affixed to 
the actuator, insertable into the respective valve body. At least one 
valve stem is attached to the projecting end of the actuator rod, with 
plugs on the opposite side of the bonnet from the actuator. The bonnet 
includes a valve seat for engagement with one of the valve plugs when that 
valve plug is actuated to a predetermined position by the actuator. Thus 
the invention replaces a single, expensive, multiple-actuator 
block-and-bleed valve with several simple, inexpensive single-actuator 
valves which together are substantially less expensive than the single 
valve they replace, while still preventing the mixing of different types 
of fluids, even on failure of one valve seat or valve plug.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to FIG. 1, there is shown a manifold assembly 10, employing a 
number of manifold valve assemblies 12 constructed according to one 
embodiment of the invention. As there shown, the manifold assembly 10 is 
connected to and receives supply from a number of sources 14, such as 
tanks of fluid. The manifold assembly 10 is also connected to and supplies 
the fluid to a number of destinations 16, such as filler machines for 
filling containers with one or more of the fluids from the fluid supply 
tanks. The purpose of the manifold assembly 10 is to control and 
selectively permit the flow of fluid from one or more predetermined 
sources 14 to a predetermined destination 16. The manifold assembly 
includes one supply tube 18 for each fluid supply source 14, and one 
delivery tube 20 for destination 16. While the manifold assembly 10 shown 
in FIG. 1 includes only two supplies 14 and two destinations 16, it will 
be understood that the invention may be equally well applied to any number 
of supplies and destinations. 
As can be seen from FIG. 1, this manifold assembly results in a crossed 
pattern of supply tubes 18 and delivery tubes 20. The supply tubes 18 and 
delivery tubes 20 do not actually intersect, but rather are positioned 
parallel in sets, in parallel planes, with either one set or the other 
being in the upper plane, the opposite set being in the lower plane. 
According to the embodiment of the invention shown in the drawing figures, 
the delivery tubes 20 are positioned in a plane beneath the plane of the 
supply tubes 18, but it could just as easily be the other way around. One 
manifold valve assembly 12 is provided at each crossing point of a supply 
tube 18 with a delivery tube 20. 
As shown best in FIGS. 2 and 3, each manifold valve assembly 12 includes in 
effect two separate valve bodies, a delivery valve body 22 and a supply 
valve body 24. Each of these valve bodies 22, 24 is supplied with its own 
actuator assembly 26, 28 respectively. As shown in FIGS. 2 and 3, these 
valve bodies 22, 24 are connected by a short crossover tube 30. As can 
best be seen in FIG. 3, this crossover tube 30 is positioned at the very 
bottom of each valve body, and oriented substantially horizontally between 
the two. Also as shown in FIG. 3, because the supply tubes 18 are 
positioned in a plane higher than that of the delivery tubes 20, the 
supply valve body 24 is longer than the delivery valve body 22, by 
approximately the diameter of the delivery tube and the vertical spacing 
between the delivery tube and the supply tube. 
The interior detail of each valve body can been seen by reference to FIGS. 
4 and 5. FIG. 4 shows the detail of the delivery valve body 22, while FIG. 
5 shows the detail of the supply valve body 24. Reference will first be 
had to the detail of the delivery valve body 22, and this detail will 
later be related to the detail of the supply valve body 24. 
As indicated above, referring particularly to FIG. 4, delivery valve body 
22 includes its own actuator 26, having an actuator rod 32, actuatable 
between two positions. Valve body 22 has, at its top, a pass-through 
section including an inlet 36 substantially aligned with an outlet 38. 
Relating FIG. 4 with FIG. 1, the inlet 36 and outlet 38 of the delivery 
valve body 22 connect to and in effect form part of one of the delivery 
tubes 20, permitting free flow of fluid to fluid destinations 16 from 
upstream destination valves at all times. 
As is not uncommon in sanitary valves, a valve stem 33 is attached to 
actuator rod 32 by any suitable, removable means, such as by a threaded 
attachment. Two valve plugs, an upper plug 40 and a lower plug 42, are 
attached to or integrally formed with the valve stem 33, both plugs 
positioned within a valve cavity 44 of the delivery valve body 22 after 
assembly of the valve stem to the actuator rod 32. Lower plug 42 is 
positioned on valve stem 33 to be capable of closing a drain port 46 at 
the bottom of valve cavity 44, while upper plug 40 is positioned thereon 
to be capable of closing a cavity outlet port 48 at the top of the valve 
cavity. The actuator 26 basically has two positions, one where drain port 
46 is open and cavity outlet port 48 is closed, and the other where drain 
port 46 is closed and cavity outlet port 48 is open. Valve cavity 44 also 
has a cavity inlet port 50, which communicates with crossover tube 30, 
shown in FIGS. 1 and 2. 
As also indicated above, referring now mainly to FIG. 5, supply valve body 
24 has its own actuator 28. As with delivery valve body 22, again actuator 
28 has an actuator rod 52, actuatable between two positions. Supply valve 
body 24 has, at its top, a pass-through section including an inlet 54 
substantially aligned with an outlet 56. Relating FIG. 5 with FIG. 1, the 
inlet 54 and outlet 56 of the supply valve body 24 connect to and in 
effect form part of one of the supply tubes 20, permitting free flow of 
fluid from fluid sources 14 to downstream supply valves at all times. 
As with delivery valve body 22, actuator rod 52 has affixed thereto a valve 
stem 53, by any suitable removable means, such as by threading. Two valve 
plugs, an upper plug 58 and a lower plug 60, are affixed to or integrally 
formed with the valve stem 53. Once the valve stem 53 is assembled to the 
actuator rod, both plugs 58, 60 are positioned within a valve cavity 62 of 
the supply valve body 24. Lower plug 60 is positioned on valve stem 53 to 
be capable of closing a drain port 64 at the bottom of valve cavity 62, 
while upper plug 58 is positioned to be capable of closing a cavity inlet 
port 66 at the top of the valve cavity. As was the case with delivery 
actuator 26, supply actuator 28 has two positions, one where drain port 64 
is open and cavity inlet port 66 is closed, and the other where drain port 
64 is closed and cavity inlet port 66 is open. Valve cavity 62 also has an 
cavity outlet port 68, which communicates via crossover tube 30 with 
cavity inlet port 50 of delivery valve body 22, shown in FIGS. 1, 2 and 4. 
Thus when cavity inlet port 66 is closed, the fluid in inlet 54 is not 
permitted to enter cavity 62, and continues out outlet 56, possibly to the 
next manifold valve assembly 12. When actuator 28 moves actuator rod 52 to 
its other position, taking valve stem 53 and valve plugs 58, 60 with it, 
cavity inlet port 66 is opened and drain port 64 is closed, permitting 
flow of fluid into the cavity 62 via the cavity inlet port 66 and 
permitting flow of the fluid out of the cavity via cavity outlet port 68. 
Control of the two actuators 26 and 28 is coordinated so that when cavity 
outlet port 48 of delivery valve body 22 is open, cavity inlet port 66 of 
supply valve body 24 is also open. Fluid then flows from supply tube 18 
into supply valve cavity 62, through crossover tube 30, into delivery 
valve cavity 44, and finally into delivery tube 20. 
Since as indicated above the length of the body of the valve bodies 22, 24 
is different, correspondingly the length of the delivery valve stem 33 
must differ from the length of the supply valve stem 53 by the same 
amount. That is, because the supply valve body 24 is longer than the 
delivery valve body 22, the delivery valve stem 53 will also be longer 
than the supply valve stem 33 by about the same amount. As can be seem by 
comparing FIG. 4 to FIG. 5, that difference is applied to the distance 
between respective pairs of valve plugs, so that the distance between 
delivery valve plugs 40 and 42 is smaller than the distance between supply 
valve plugs 58 and 60 by substantially the same amount. 
As indicated above, the actuators 26, 28 are coordinated to normally work 
together. Otherwise the supply valve cavity inlet port 66 could be open 
while delivery valve cavity outlet port 48 is closed, causing supply fluid 
to drain continuously out delivery valve drain port 64. Accordingly, any 
malfunction of any part of the manifold valve assembly 12 must be quickly 
restored to proper function to minimize waste. However, once the number of 
manifold valve assemblies 12 is assembled into the manifold assembly 10, 
usually by welding, there would be no practical means to easily remove 
and/or replace a single valve body. 
Therefore the invention calls for structure permitting easy removal of the 
actuator and valve stem from any one of the valves at any time. This 
feature of the invention can best be set forth by reference to FIG. 6, 
using a delivery valve body 22 as an example, although it clearly applies 
equally to the supply valve body 24 in this embodiment. As shown there, 
the body 22 is formed by the assembly of a valve bonnet 70 into a valve 
body proper 72, the latter having substantially all the ports 36, 38, 46, 
50 referred to above. The only port formed specifically by the bonnet 70 
is the cavity outlet port 48, in the following manner. 
The valve stem 33 is inserted upward through an opening 78 in the bonnet 70 
and attached to actuator rod 32. The actuator 26, with the valve stem 33 
attached to its actuator rod 32, is then affixed to a flat top surface 74 
of the bonnet by any suitable removable means, such as threaded fasteners 
76. The bonnet 70 has a flange 80 which flares outward from the central 
opening, to fit onto a mating flange surface 82 of the body proper 72. 
Upon assembly the two flanges are clamped together by a suitable clamp 84 
(FIG. 4). An annular ridge 83 is provided in the facing surface of the 
bonnet flange 80, which engages a matching annular channel 85 formed in 
the facing surface of the mating flange surface 82, to aid in alignment 
and assembly. Beyond the flange 80, the bonnet 70 includes a shoulder 86 
which, together with a facing shoulder structure 88 in the body proper 72, 
permits spacing for sealing means, such as an O-ring 90 (FIG. 4). After 
the shoulder 86, the bonnet 70 has a cage portion 92, with large openings 
or gaps alternating with separated bars 93. The cage portion 92 is about 
the same in length as the inlet port 36 and outlet port 38 are in width. 
The bonnet 70 then terminates in a ring portion 94, which contacts a 
corresponding ledge 96 in the body proper 72, via another sealing means 98 
(FIGS. 4 and 6). In its preferred form, sealing means 98 can best be 
described as either a gasket having enlarged side edges or a pair of 
O-rings integrally connected by a web. The ring portion 94 has an inner 
beveled area 100 at its distal end which constitutes a valve seat into 
which plug 40 is sized to tightly fit. 
Once valve stem 33 is inserted through opening 78 in bonnet 70 and attached 
to actuator rod 32, the entire assemblage is then inserted into the body 
proper 72 and clamped therein. Just as easily, if the actuator 26 requires 
service, or if the valve plugs 40, 42 need replacing or other service, the 
clamp 84 is opened and the actuator and bonnet 70 removed. 
Thus the structure of the present invention replaces a single, expensive, 
multiple-actuator valve with a pair of simple, inexpensive single-actuator 
valves which together are less expensive than the single valve they 
replace, while still preventing the mixing of different types of fluids, 
even on failure of one valve seat or valve plug. It is not uncommon for 
the single valve of the prior art to be three times as expensive as one of 
the simple valves provided by the present invention. Accordingly, even 
though the present invention requires in effect two valves where the prior 
art used one, the cost of the structure of the present invention is still 
less than the prior art by a third or more. 
It is not unusual for the delivery tubes 16 to be smaller in size than the 
supply tubes 14, such as 2 inch delivery tubes being used with 3 inch 
supply tubes. In order to satisfy sanitary requirements, it is necessary 
that the total drain opening area of the manifold valve assembly 12 is at 
least as large as the smaller of the supply tubes 14 or the delivery tubes 
16. In most prior art valves, this requirement adds to the expense of the 
valve, requiring a large single opening. In the structure provided by the 
present invention, however, in effect two drain ports are provided, one 
drain port 46 in the delivery valve body 22 and one drain port 64 in the 
supply valve body 24. It is the sum of the areas of these two drain ports 
that must at least equal the area of the smaller of the supply tube 14 or 
delivery tube 16. Each separate drain port 46, 64 can, then, be 
substantially smaller than either the supply tube 14 or the delivery tube 
16. This has the further advantage of permitting the relative reduction of 
the size of the valve cavities 44, 62, reducing waste of product. Waste is 
reduced because each time the valve actuators 26, 28 switch from open to 
closed, the entire volume of fluid in both valve cavities 44, 62 is 
drained out the respective drain port. If the volume of these cavities is 
reduced, the volume of fluid wasted in switching is also reduced. Even 
further, as shown in FIG. 7, a bonnet 70a may be provided with a smaller 
seat 100a, the diameter of the seat being reduced to substantially the 
size of the delivery tube 20. This bonnet 70a permits reduction of the 
size of the plug 40a, further reducing waste. 
FIGS. 8 through 11 show manifold valve structure to accomplish the same 
objects, but from a slightly different approach. In the embodiments shown 
in those figures, only one specialized valve body is used, with the 
remaining control provided by simple shut-off valves. 
Referring particularly to FIG. 8, there is shown a manifold valve assembly 
112 having a supply valve body 24 exactly as described above with 
reference to FIGS. 1 through 3 and particularly FIG. 5. In this 
embodiment, however, supply valve cavity outlet port 68 is connected to a 
short length of tubing 114 and an elbow 116, in turn connected to the 
inlet 118 of a conventional shut-off valve 120. The type of shut-off valve 
120 selected is the type with a T-body, as the shut-off valve still needs 
to be connected into the delivery tube 20 and permit pass-through of the 
fluid in the delivery tube Hence the flow within manifold valve assembly 
112 begins when actuator 28 opens cavity inlet port 66 and closes drain 
port 64. At the same time shut-off valve actuator 126 withdraws plug 142 
from shut-off valve outlet port 148. The fluid flowing into cavity 62 then 
continues and flows through tubing 114 and elbow 116, and thereby through 
shut-off valve 120 and into delivery tube 20. 
It will be noted that the embodiment shown in FIG. 8 is applied to the 
situation where the plane of the supply tubes 18 is above the plane of the 
delivery tubes 20. As indicated earlier, either set of tubes may be in the 
upper plane. If the plane of the supply tubes 18 is below that of the 
delivery tubes 20, the manifold valve assembly 212 shown in FIG. 9 is 
used. Manifold valve assembly 212 includes a supply valve body 222 
substantially identical to delivery valve body 22 (FIGS. 1 through 4 and 
6), including the fact that the valve cavity 244 is shorter than the valve 
cavity 62 of supply valve 24 (FIG. 8). The only difference is the way the 
valve body 222 is connected into the manifold 10, that is, in such a way 
that the flow within the valve body is reversed from that described in 
reference to delivery valve body 22. In particular, when actuator 228 
opens cavity inlet port 266 and closes drain port 264, shut-off valve 
actuator 126 simultaneously withdraws plug 142 from shut-off valve outlet 
port 148. The fluid flowing into cavity 244 then continues and flows 
through tubing 114 and elbow 116, and also through an extension 117 which 
must be provided because shut-off valve 120 is higher in assembly 212 than 
in assembly 112 to align with the relatively higher delivery tube 20. The 
fluid is thereby passed through shut-off valve 120 and into delivery tube 
20. 
The embodiments shown in FIGS. 8 and 9 have a slight advantage over that 
shown in the earlier drawing figures in that since there is no second 
specialized valve body, the amount of fluid inside the manifold valve 
assembly 112 or 212 is less, reducing waste. 
Taking the embodiments shown in FIGS. 8 and 9 one step further is the 
embodiment shown in FIGS. 10 and 11. The manifold valve assembly 312 there 
shown includes three valves, two conventional shut-off valves 120 with 
T-bodies, with their inlets both connected, via respective extensions 117, 
elbows 116 and tubes 114, to separate outlets of specialized valve body 
322. Valve body 322 is substantially the same as valve body 222, with the 
exception of the second outlet, for connection to the second shut-off 
valve. This arrangement permits, with the use of only one specialized 
valve body 322, the control of flow from a source 14 to two destinations 
16, further reducing the total cost of the manifold without any loss of 
control and with reduced waste. Manifold valve assembly 312 replaces two 
of the previous, expensive valves, with a cost factor still less than one 
of those prior valves, while still preventing the mixing of different 
types of fluids running through the same valve assembly, even on failure 
of one valve seat or valve plug. 
While the apparatus hereinbefore described is effectively adapted to 
fulfill the aforesaid objects, it is to be understood that the invention 
is not intended to be limited to the specific preferred embodiment of 
manifold valve assembly with removable valve seat set forth above. Rather, 
it is to be taken as including all reasonable equivalents within the scope 
of the following claims.