Flow check valve assembly and method

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.

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'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.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown inFIGS. 1-11, the valve assembly10of the present invention includes a main body component15and a chamber body component20. 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 component15and chamber body component20are 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 component15and chamber body component20are 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 inFIGS. 2,6and7, the main body component15includes an outer wall22and an inner wall24. Together, the inner wall24and outer wall22comprise an integrated wall. The outer wall22of main body component15is capable of securely engaging the inner wall of a piping or tubing component.

The inner wall24of the main body component15includes a radially inwardly extending rampart member55having a first side wall56, a second side wall58and an interior edge60. The rampart member55assists in providing a channel51and a physical resistance structure employed by the chamber body20and 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 inFIG. 11, the rampart member second side wall58cooperates with the chamber body member20to form a positive displacement cavity59.

The interior edge60is capable of slidingly engaging the chamber body component20during operation of the present invention, as described in more detail hereafter. In one embodiment of the present invention, the inner wall24includes a tapered surface element62at the first axial end28of the main body component15. As shown inFIG. 2, the tapered surface element62begins at a taper point64extending circumferentially around the inner wall24and ends at a position66under an interior lip65of the cap edge26. In this way, the tapered surface element62and the cap edge interior lip65can engage a fluid control plate as described in more detail hereafter.

As shown inFIGS. 2 and 3, the chamber body component20includes an outer wall70and an inner wall72, together comprising an integrated wall, with the outer wall70capable of slidingly engaging the interior edge60of the rampart member55of main body component15. In this way, the chamber body component20is not permitted to veer off its axial course during operation, and space is provided appropriately between the outer wall70of the chamber body component20on both sides of the rampart member55of the main body component to permit fluid flow, as shown inFIG. 11. The chamber body component20can take the form of a substantially cylindrical body element having a channel or cavity21therethrough to permit axial flow of fluids.

The chamber body component20is also formed to include one or more propulsion ports75in 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 ports75are positioned so as to function only upon saturation of the flow area, as will be described in more detail hereafter. The outer wall70of the chamber body component20extends from a first axial end76to a second axial end78. The chamber body component20is formed to include a chamber body head member80extending radially outwardly from the outer wall70proximate the first axial end76and a gland engaging end82extending radially outwardly from the outer wall70proximate the second axial end78. As shown in the embodiment ofFIG. 3, the head member80extends substantially perpendicularly from the outer wall70while the gland engaging end82extends as indicated at83at 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 inFIG. 3, the angles shown inFIG. 3assist in structurally supporting the chamber body component20within the overall device of the present invention during operation. As shown inFIG. 3, the gland engaging end82includes an external body wall84, an outer radial wall86and an outer axial wall88. The outer radial wall86includes an inner face91and an outer face92, and the outer axial wall88includes an inner face93, an outer face94and a radial internal edge95. An annular groove100is formed by the outer radial wall inner face91, the outer axial wall inner face93and the first external body wall84of the chamber body component20. The annular groove100receives an interior lip of a gland member as described hereafter.

In one embodiment of the present invention, the radius R1of the first portion61of the main body component chamber that houses the chamber body head member80is greater than the radius R2of the second portion63of 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 plate170is located) and that occurring near the fluid inbound area (i.e., from the area where gland130is located). Additionally, in one embodiment of the present invention, the chamber body head member80has a radius R4that is slightly less than the radius R1of the first portion61of the main body component chamber, and the chamber body component20radius R5(to outer wall70, shown inFIG. 3) is slightly less than the internal radius R3of the rampart member55within main body component15. In one embodiment, the relationship of the respective radii can be such that the chamber body head member radius R4is from 0.002 to 0.015 inches less than the radius R1of the first portion61of the main body component chamber, inclusive, and chamber body component radius R5is similarly from 0.002 to 0.015 inches less than the radius R3of the rampart member55. 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 member80and component20may not slide evenly within the main body component chamber61and within the area encircled by the rampart member55, 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 inFIGS. 2 and 3, the annular groove52within the main body component15faces radially outwardly while the annular groove100within the chamber body component20faces 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 inFIGS. 1-5, the inner wall72of the chamber body component20is provided with a thread110proximate the second axial end78for receiving an end cap115as described hereafter. The inner wall72further extends through the chamber body head member80, extending radially inwardly to form an interior ring120having a first side wall122, a second side wall124and a radially inward edge126. A bevel wall128extends from the inner wall72at a position adjacent the first side wall122of the interior ring120, and the bevel wall128is angled so as to cooperatively engage a control seal during operation of the present invention, as described hereafter.

The gland member130of the present invention is shown inFIGS. 1-2and8-10. As shown therein, the gland member130comprises 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 member130is a hollow, ring-shaped device having a radially outer wall132, a radially inner wall134and an exterior wall136. The gland member130further is formed with an interior face138having a substantially C-shaped cross-section with exterior140and interior142lip elements. As shown inFIG. 10, the exterior lip140includes a front wall150, a radially inward wall152and an interior wall154, and the interior lip142includes a front wall160, a radially inward wall162and an interior wall164. Further, each of the gland member exterior wall136, radially outer wall132and radially inner wall134includes a respective inner surface144,145,146, whereby the respective inner surfaces144,145,146and the lip members140,142cooperatively engage the annular grooves52,100of the main body component15and the chamber body component20, respectively.

In one embodiment of the present invention, as shown inFIG. 10, the front wall150of the exterior lip140extends further outwardly than the front wall160of the interior lip142, and the interior wall154of the exterior lip140extends further inwardly than the interior wall165of the interior lip142. Such an arrangement provides the exterior lip140with greater surface area and thereby greater strength of connection with main body component than the interior lip142enjoys with the chamber body component20. Further, as shown in the embodiment of the present invention shown inFIG. 10, the radially outer wall132of the gland member is thicker in width and shorter in length than the radially inner wall134. As a result, the interior lip142has a modest amount of additional flexibility to thereby operate as intended, by permitting the chamber body component20to move axially within the main body component chamber. In one embodiment of the present invention, as shown inFIG. 9, the length L1of the radially inner wall132can range from approximately 125% to approximately 167% the length L2of the radially outer wall134, and the width W1of the radially inner wall132can range from approximately 20% to approximately 40% the width W2of the radially outer wall134. In a further embodiment of the present invention, the width W3of the exterior lip radially inward wall152is approximately 175% to approximately 300% the width W4of the interior lip radially inward wall162.

As shown inFIGS. 2,4and5, a chamber cap115is provided in the form of a substantially cylindrical-shaped body205having a cavity208extending axially therethrough with a head portion210at one end212of the body205. The head portion210can be of any shape that can be manipulated for clockwise and counter-clockwise rotation, and is shown inFIG. 4in a hexagonal shape. The body portion205is provided with an external thread214for mating with the internal thread110of the chamber body component20.

In one embodiment of the present invention as shown inFIGS. 1,2and11, a fluid control plate170is designed with one or more fluid control plate flow ports172to allow fluid to flow therethrough. The fluid control plate170can receive a flow restrictor180extending through a central axial opening173of the plate, and the flow restrictor180thereby extends axially inwardly and into the first portion61of the cavity of the main body component15. In one embodiment of the present invention, the flow restrictor180includes a flood stop control seal or plunger seal182that assists in sealing the fluid flow during operation of the device, when required. As shown inFIGS. 1,2and11, the control seal182can have a wider flow-facing end186tapered to a narrower downstream end184. The outer edge188of the flow-facing end186of the control seal180is adapted to mate with the bevel wall128of the chamber body component20in substantially flush relation during operation if and when the valve is positioned in shut-off position. The flow restrictor180includes a neck portion189that securely fits within central axial opening173of the plate, as shown inFIGS. 1 and 11. The edge175of the fluid control plate170can be considered a stabilizer edge and wall174can be considered a snap slope edge in that the fluid control plate can snap into position within the main body component15as a result of the tapered surface element62in the main body member inner wall24, as shown inFIG. 11. In one embodiment of the present invention, the fluid control plate170and the flow restrictor180with flood stop control seal182are separate components, with the flow restrictor180being insertable and retainable within fluid control plate170by pushing downstream end184through the central axial opening173of the fluid control plate170. An upstream central plug element189of the flow restrictor180is also provided and can assist with restricting fluid flow during operation as the chamber body component20is pushed towards the flow restrictor180, as the ring extension124surpasses and encircles the plug element189if 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 plate170can be formed of a polymeric material such as polyoxymethylene (POM) and the flow restrictor180with flood stop control seal182can be formed of EPDM rubber (ethylene propylene diene monomer (M-class) rubber) material. Similarly, the gland member130described 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 component20is inserted through an opening190at the first axial end28of the main body component15, and the fluid control plate170with flow restrictor180and flood stop control seal182is inserted and secured into the cap portion26of the main body component15. The gland member130is secured to the main body component15and the chamber body component120such that the external140and internal142lips of the gland member130securely engage the annular grooves52,100described above. The chamber cap115is then inserted through the gland member130such that the external thread214on the chamber cap115securely engages the internal thread110on the chamber body component20.

In operation, fluid such as water enters from a piping or tubing element (not shown) into the valve assembly10of the present invention from the first axial end of the main body component15. 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 assembly10is unaffected and permits free flow through the cavity of the chamber body component20and past the flow stop control seal182and through the ports172in the fluid control plate170. If the incoming fluid flow increases, fluid pressure will build up outside of the chamber body component20and will extend around the end of the chamber body component (for example, in the areas250around the head portion205of the chamber cap115) to push the chamber cap115towards the fluid control plate end of the assembly. In this process, the chamber body component20will come closer to the fluid sealing member182, and the gland member130will stretch to permit the extension of the chamber body component. Additionally, propulsion ports75will move from a position where they permit fluid to evacuate the chamber body member into channels255inFIG. 11alongside chamber body component20, to where they permit fluid to evacuate the chamber body member20in the positive displacement cavity59and first portion61of the chamber of the main body component15beyond the rampart member55of the main body member15. The propulsion ports75thus facilitate some evacuation of fluid from the chamber body member20, but ultimately allow the fluid to continue building up and pushing the chamber body member20towards the fluid control seal182, since the positive displacement cavity59is relatively small, and the chamber body member will be pushed by fluid within cavity61as the fluid pressure builds up against chamber head portion80. It will be appreciated that some balancing fluid flow may occur through slender channels193,195shown inFIG. 11, assisting with back pressure for the device.

When the fluid flow is so great that the fluid control seal182seals against the seal engaging bevel edge128of the chamber body component20, no more fluid can exit through the fluid control plate170. Once the flow rate is reduced externally (e.g., from the incoming area250inFIG. 11), the pressure on the chamber body component20is relaxed, and the chamber body component is returned via pressure from the gland member130away from the fluid control seal182.

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.