An improved one-way fluid valve construction is provided. A valve housing (102) includes one or more valve ports (108) and control ports (110). A control member (304) is disposed within the control port (110). The control member (304) is movable within the control port (110) between a first position and a second position. A control rod (302) can extend between the control member (304) and a portion of the valve port (108). A control rod coupling (402) interacts with the control member (304) to cause a rotational or pivotal movement the control rod (302) through a predetermined angular arc in response to movement of the control member (304). A sealing face (404) formed on a second portion of the control rod (302) advantageously forms a seal with an orifice (316) that separates an input side of the valve port (108) from an output side. The seal can be formed when the control rod (302) is in a control rod sealed position. When the control rod (302) is rotated to a control rod unsealed position, the sealing face unseals from the orifice (316).

BACKGROUND OF THE INVENTION

1. Statement of the Technical Field

The invention relates generally to check valves, and more particularly to an improved straight flow one-way valve for use as an intake or discharge (or delivery) valve in fluid compressors.

2. Description of the Related Art

Fluid compressors are used in a wide variety of industrial and commercial applications. Some types of fluid compressor, such as reciprocating piston systems, typically require the use of some type of valve to control a flow of air. One type of valve that is commonly used in fluid compressors is called a check valve. Check valves generally allow a fluid, such as air, to pass in a first direction, but do not allow fluid to flow in an opposite direction. For example, such valves are often positioned so that a first valve allows fluid to flow into a cylinder of a reciprocating piston compressor during an intake stroke. A second valve is typically positioned for allowing fluid to flow out of the cylinder during a compression stroke.

A variety of different check valve designs have been proposed over the years. For example, U.S. Pat. No. 4,036,251 to Hartwick et al. discloses such a check valve. Still, there are a number of key design criteria for check valves that are subject to improvement. One design goal is increasing the equivalent orifice size of the check valve. Equivalent orifice is a term that compares the resistance that a fluid encounters passing through a valve opening to the resistance of a circular opening in a thin plate through which the same quantity of fluid flows under the same pressure. Another design goal is to improve reliability and longevity of the valve. Yet another design goal is to improve the manufacturability of high flow check valves.

SUMMARY OF THE INVENTION

The invention concerns an improved one-way fluid valve construction. The one way fluid valve construction is formed from a valve housing that includes at least one valve port and at least one control port. Each of the valve port and the control port define a hollow passage extending from an inlet face of the valve housing to an outlet face of the valve housing.

A control member is disposed within the control port. The control member can have first and second faces. A first face can be in fluid communication with the inlet face of the valve housing and a second face can be in fluid communication with the outlet face of the valve housing. The control member is advantageously arranged so that it is movable within the control port between a first position and a second position. A resilient member is provided that can bias the control member toward the first position. The control member can transition from the first position to a second position upon the occurrence of a predetermined fluid pressure differential as between the inlet face and the outlet face. For example, the transition can be a linear sliding motion that can occur within the control port.

A control rod is provided that is rotatably journaled within the housing. The control rod can extend between the control member and a portion of the valve port. The control rod advantageously has a coupling at a first portion adjacent to the control member. The coupling can directly or indirectly engage a portion of the control member. Consequently, the control member can cause a rotational or pivotal movement of the control rod through a predetermined angular arc. This rotational movement occurs when the control member transitions between the first position and the second position. In one embodiment of the invention, the coupling comprises a plurality of gear teeth that engage a complementary plurality of gear teeth on control member. In another embodiment of the invention, the coupling comprises a single tooth that engages a notch on the control member.

A sealing face is formed on a second portion of the control rod that extends into the valve port. The sealing face can advantageously form a seal with an orifice that separates an input side of said hollow passage from an output side of the hollow passage. The seal can be formed when the control rod is in a control rod sealed position. When the control rod is rotated to a control rod unsealed position, the sealing face unseals from the orifice.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIGS. 1 and 2, shown is a one-way fluid valve100for use as a fluid intake or check valve for a fluid compressor. In one embodiment of the invention, the valve100is designed for use in the intake or delivery side of a fluid compressor, although other uses will be apparent to one of ordinary skill in the art. The valve100is formed partially from a valve housing102. The valve housing102is generally formed of metal. However, the invention is not limited in this regard as to the material selected for the valve housing102.

The valve housing102has in inlet face104and an outlet face106. The inlet face104and outlet face106are disposed on opposing sides of the valve housing102. The valve housing102also includes at least one valve port108and at least one control port110. Each of the valve ports108and the control ports110define a hollow passage that extends from the inlet face104of the valve housing102to the outlet face106of the valve housing102. The hollow passage associated with the control ports110is a cavity112. The hollow passage associated with the valve ports108is a flow channel113(see alsoFIG. 3B). In the embodiment shown, there is one control port110located between opposing pairs of valve ports108. Each control port110is associated with a pair of control rods302(best seen inFIG. 3A) which control the flow of intake air into the valve ports108and the fluid compressor (not shown). The number of valve ports108and control ports110are selected according to a desired amount of air flow through valve100into the fluid compressor (not shown). For example, inFIG. 1, there are three control ports110and twelve valve ports108. Still, the invention is not limited in this regard.

Referring now toFIGS. 3A and 3B, it can be observed that a control member304is disposed within the cavity112of each of the control ports110. The control members304can have first and second faces306,308. The first face306can be in fluid communication with the inlet face104of the valve housing102and the second face308can be in fluid communication with the outlet face106of the valve housing. The control member304is advantageously arranged so that it is movable within the cavity112of control ports110between a first position and a second position. For example, inFIG. 3A, one of the control members304A is shown in a first position, and a second one of the control members304B is shown in the second position. InFIG. 3A, the control members304will generally be in the first position when the fluid pressure on the inlet face104is less than the fluid pressure at the outlet face106by a predetermined amount.

Note that control members304are shown concurrently in different positions inFIG. 3Ato facilitate an understanding of the invention. It should be understood that in actual operation of the valve100, all control members304will be generally in the same relative position at any given moment. For example, all of the control members304will generally be in the first position when the fluid pressure on the inlet face104is less than the fluid pressure at the outlet face106by a predetermined amount. Conversely, all of the control members304will generally be in the second position when the fluid pressure on the inlet face104is greater than the fluid pressure at the outlet face106by a predetermined amount.

Each control member304is resiliently biased toward the inlet face104with a resilient member310. In one embodiment of the invention, the resilient member310is a spring. When the control member304is in a first position, fluid is prevented from traveling through flow channel113from the inlet face104to the outlet face106. When the fluid pressure exerted on first face306exceeds the fluid pressure exerted on second face308by an amount corresponding to the biasing force of the resilient member310, the control member304will transition from the first position to the second position. The movement of control member304is linear along a path defined by the cavity112of the control port110. The control member304slides within the cavity112between the first position and the second position, depending upon the pressure differential between the inlet face104and the outlet face106.

At least one control rod302is coupled to each of the control members304. InFIG. 3A, two control rods302are coupled to each of the control members304A and304B. However, the invention is not limited in this regard. There could be a single control rod302coupled with a single control member304A or304B (not shown). In any case, the control rods302are rotatably journaled within the housing102and can extend transversely from one or both sides of the control member304. More particularly, the control rods302can extend to adjacent pairs of valve ports108that are disposed on either side of the control ports110. Further, each control rod302can be formed as a single unit or can be formed from two or more sections. For example, the control rod302can be bisected along line5-5(FIG. 4A). A section320of a control rod302that could form a control rod302is shown inFIGS. 7A-7B. Still, the invention is not limited to any particular construction with respect to the control rod302.

Referring now toFIGS. 4A and 4B, shown are top and side elevation views, respectively, of the control rod302. The control rod302is comprised of an elongated rod-like member. Two or more annular guide channels408can be provided for maintaining the control rod302in proper alignment with housing100and the various ports108,110. The annular guide channels408can engage rib portions (not shown) of the control member304to prevent lateral movement of the control rod102. In addition, there are seal channels409disposed on each of the opposing ends of the control rod302. There can be more seal channels409disposed adjacent to each of the guide channels408. The seal channels409are for receiving a seal such as an o-ring to prevent the leakage of compressed air from the valve housing102(FIG. 1). Control rod302also includes at least one sealing face404disposed on a portion of the control rod302. A plurality of ribs406can be provided on the control rod302for ensuring greater structural rigidity. There is at least one land412opposite each of said at least one sealing face404. The at least one land412is connected to said at least one sealing face404by at least one bridge411for even greater structural rigidity. The sealing face404and plurality of ribs406are also shown inFIG. 6, which is a cross-sectional view of the control rod302, taken along line6-6. Alternately, the control rod302be constructed without the at least one land412and at least one bridge411connecting the at least one land412to the at least one sealing face (not shown). This construction of a control rod302may be desirable to reduce overall material and manufacturing costs. In addition, the inner seal channel409adjacent to guide channel408on control rod302may be eliminated (not shown) to reduce manufacturing costs and overall complexity.

Referring now also toFIG. 3A, it can be observed that each control rod302advantageously has a coupling402(FIGS. 4A-4B) at a first portion that is disposed adjacent to a control member304when the control rod302is positioned within the valve housing102. The coupling402(FIGS. 4A-4B) can directly or indirectly engage a portion of the control member304. InFIG. 3A, the coupling402(FIGS. 4A-4B) is comprised of a plurality of gear teeth312that are provided on a surface of the control rod302. The plurality of gear teeth312are shown inFIG. 3Aand inFIG. 5, which is a cross-sectional view of the control rod302taken along line5-5. A corresponding plurality of gear teeth314are also formed on a shaft of each control member304. The plurality of gear teeth312on control rod302engage the plurality of gear teeth314on control member304. Consequently, the movement of control member304can cause a rotational or pivotal movement of the control rod302through a predetermined angular arc of rotation. This rotational movement occurs when the control member304transitions between the first position and the second position. Notwithstanding that the coupling402is shown as a plurality of gear teeth312, it should be understood that the invention is not limited to that specific type of coupling arrangement. In fact, any suitable coupling can be used for this purpose, provided that it is capable of translating the movement of the control member304to a rotational movement of the control rod302as previously described herein. Another embodiment of a coupling arrangement is shown inFIG. 3Cand described in detail hereinbelow.

Referring again toFIG. 3A, and also to FIGS.3B and4A-4B, it can be observed that the sealing face404of the control rod302can extend into the valve port108when the control rod is positioned within the housing102. The sealing face404can advantageously form a seal with an orifice316formed in each valve port108. For example, the seal can be formed by engagement of the sealing face404and a perimeter of the orifice316. The seal can provide a fluid barrier that seals an input side of the flow channel113defined by the valve port108from an output side of the flow channel113. The seal can be formed when the control rod302is in a control rod sealed position. When the control rod302is rotated to a control rod unsealed position, the sealing face unseals from the orifice316. For example, the control rod302can be rotated to the control rod sealed position when the control member304is in the first position shown by control member304A. The control rod302can be rotated to the control rod unsealed position when the control member304is in the second position shown by control member304B.

Referring toFIG. 3C, another embodiment of a one-way fluid valve100for use as a fluid intake or check valve for a fluid compressor is shown. The one-way fluid valve100is identical to the one-way fluid valve100of the previous embodiment except that there is an alternate coupling arrangement for coupling control member304to control rod302. Specifically, a control member304is disposed within a cavity112of each of the control ports110. The control members304can have first and second faces306,308. The first face306can be in fluid communication with the inlet face104of the valve housing102and the second face308can be in fluid communication with the outlet face106of the valve housing. The control member304is advantageously arranged so that it is movable within the cavity112of control ports110between a first position and a second position. Each control member304is resiliently biased toward the inlet face104with a resilient member310. In one embodiment of the invention, the resilient member310is a spring. Each control member304can be of a two piece construction comprised of a top cap member305and a lower piston member307to facilitate assembly in valve body102.

The alternate coupling arrangement is comprised of a coupling402(FIGS. 4A-4B) on control rod302which could be comprised of a single tooth111that engages a notch or lip303that is formed on the control member302. Consequently, the movement of control member304can cause a rotational or pivotal movement of the control rod302through a predetermined angular arc of rotation. This rotational movement occurs when the control member304transitions between the first position and the second position. InFIG. 3C, one of the control members304A is shown in a first position, and a second one of the control members304B is shown in the second position. The control members304will generally be in the first position when the fluid pressure on the inlet face104is less than the fluid pressure at the outlet face106by a predetermined amount. Note that control members304are shown concurrently in different positions inFIG. 3Cto facilitate an understanding of the invention. It should be understood that in actual operation of the valve100, all control members304will be generally in the same relative position at any given moment.

Referring toFIG. 3D, another embodiment of a one-way fluid valve100for use as a fluid intake or check valve for a fluid compressor is shown. The one-way fluid valve100is similar to the one-way fluid valve100ofFIG. 3Aexcept that the control rods302are staggered in height between adjacent control ports110. For example, inFIG. 3D, there is a control member304C disposed in a control port110that is disposed higher in valve body102than the adjacent control member304B and control port110. Consequently, the control rods302disposed adjacent to control member304C are disposed higher in valve body102than the control rods302disposed adjacent to control member304B. Similarly, the control rods302disposed adjacent to control member304A are disposed higher in valve body102than the control rods302disposed adjacent to control member304B. The reason for this staggered construction of control rods302between adjacent control members304is to ensure that there is enough material in valve body102between adjacent control rods302to ensure the structural integrity of valve body102during construction and operation.

In all other respects, the construction of one way fluid valve100is identical. For example, each control member304is disposed in a hollow passage112, has a first face in fluid communication with the inlet face104of the valve housing102, and a second face308in fluid communication with an outlet face308. Each control member304is resiliently biased toward the inlet face with a resilient member310. Each control member304is coupled to at least two control rods302rotatably journaled within the housing102. Each control member304causes a rotational or pivotal movement of the adjacent control rods302through a predetermined angular arc of rotation. Each control member304can be of a two piece construction comprised of a top cap member305and a lower piston member307to facilitate assembly in valve body102.

Referring now toFIG. 3E, there is shown yet another embodiment of a one-way fluid valve120for use as a fluid intake or check valve for a fluid compressor. The one-way fluid valve120is similar to the one-way fluid valve100ofFIG. 3Aexcept that the valve body125is of a one-piece construction and control members304are retained within the respective hollow passages112by a plate126disposed on the top of the valve body125. At least one plug128is inserted between plate126and control members304for retaining control members304in hollow passages112. One or more retaining members127such as bolts can be used to secure plate126to valve body125. Note that control members304A and304B are shown concurrently in different positions inFIG. 3Eto facilitate an understanding of the invention. It should be understood that in actual operation of the valve120, control members304A and304B will be generally in the same relative position at any given moment.

In all other respects, the construction of one way fluid valve120is identical to the one-way fluid valve100ofFIG. 3A. For example, each control member304is disposed in a hollow passage112, has a first face306in fluid communication with the inlet face104of the valve housing103, and a second face308in fluid communication with an outlet face308. Each control member304is resiliently biased toward the inlet face with a resilient member310. Each control member304is coupled to two control rods302rotatably journaled within the valve housing103. Each control member304causes a rotational or pivotal movement of the adjacent control rods302through a predetermined angular arc of rotation. Each control member304can be of a two piece construction comprised of an upper piston member317and a bottom cap member318to facilitate assembly in valve body125.

Referring now toFIGS. 7A-7BandFIGS. 4A-4B, shown are top and side elevation views, respectively, of a section320of a control rod302like the control rod302shown inFIGS. 4A-4B. When a section320of a control rod302is combined with another section320of a control rod302a complete control rod302is formed. Like the control rod302shown inFIGS. 4A-4B, each section320of a control rod302is provided with an annular guide channel408for maintaining the section320of a control rod302in proper alignment with housing100and the various ports108,110. The annular guide channel408can engage a rib portion (not shown) of the control member304to prevent lateral movement of the control rod102. In addition, there is a seal channel409disposed on the end of the control rod302. There can be another seal channel409disposed adjacent to the guide channel408. The seal channels409are for receiving a seal such as an o-ring to prevent the leakage of compressed air from the valve housing102(FIG. 1). Each section320of the control rod302also includes at least one sealing face404disposed on a portion of the control rod302. A plurality of ribs406can be provided on the each section320of the control rod302for ensuring greater structural rigidity. There is at least one land412opposite each of said at least one sealing face404. The at least one land412is connected to said sealing face404by at least one bridge411for structural rigidity. The sealing face404and plurality of ribs406are also shown inFIG. 8, which is a cross-sectional view of the section320of the control rod302, taken along line9-9.

A number of references are cited herein, the entire disclosures of which are incorporated herein, in their entirety, by reference for all purposes. Further, none of these references, regardless of how characterized above, is admitted as prior art to the invention of the subject matter claimed herein.