Fluid control valve system and methods

A diaphragm-type control valve having a valve body holding a diaphragm and a depression member is provided preferably for use in the separation of and fluid control between a fluid source and a pressurized gas volume. An inner surface of the valve body defines a chamber having an inlet and an outlet in communication with the chamber, and an elongated seat member. The depression member biases the diaphragm to a seated position within the valve.

FIELD OF INVENTION

This invention relates generally to valves and the control of water supply systems. More specifically, the invention is directed to valves using a diaphragm to control flow through the valve, and the formation of a seal within the valve.

BACKGROUND OF THE INVENTION

Diaphragm-type fluid control valves can provide controlled fluid separation and flow along a pipe-line, manifold or other piping network. Generally, the diaphragm-type valve includes a flexible diaphragm element molded from an elastomeric material to control fluid flow between the inlet and the outlet of the valve body. More specifically, in known diaphragm-type valves, the diaphragm element engages a seat formed within the valve body to separate the interior chamber of the valve body into three parts: (i) an inlet chamber which can hold the supply fluid, (ii) an outlet chamber which receives fluid from the inlet chamber for discharge out the outlet and (iii) a diaphragm chamber which can hold a fluid under pressure to urge and maintain the diaphragm element in the seated position. Upon release of fluid pressure from the diaphragm chamber, the diaphragm element can be displaced from the seated position by the pressure of fluid in the inlet chamber and fluid flow is permitted between the inlet and the outlet chambers. Known diaphragm elements and diaphragm-type control valves are shown and described in European Patent Application No. EP 0928917; U.S. Pat. No. 6,095,484; U.S. Pat. No. 7,059,578; and U.S. Pat. No. 8,616,234. The known diaphragm elements show and describe structures formed with the diaphragm elements to facilitate seating of the diaphragm element within the valve body. For example, U.S. Pat. No. 6,095,484 shows and describes a diaphragm element formed with a central ring and radially extending springy ribs to facilitate seating of the diaphragm element. U.S. Pat. Nos. 7,059,578 and 8,616,234 show and describe a diaphragm element formed with the radially arranged ribs and a ring element which facilitate seating of the diaphragm element. The seating structures can add to the complexity of forming or molding the diaphragm element.

SUMMARY OF THE INVENTION

Preferred embodiments of a diaphragm-type control valve include a preferred diaphragm element and a separate depression member which engages the diaphragm element to facilitate or bias the diaphragm element to its seated position within the valve. By employing a separate depression member, the manufacturing of the diaphragm element can be simplified by eliminating the need to form or mold the additional seat facilitating structures. Alternatively, the preferred depression member can supplement or enhance the function of a seat facilitating structure formed in the diaphragm element. In one preferred embodiment of the invention, a diaphragm-type control valve is provided that has a valve body defining an internal chamber and an inlet and an outlet communicating with the chamber. The chamber encloses a diaphragm disposed to control flow between the inlet and outlet by moving the diaphragm between a first position allowing flow through the valve and a second position that inhibits flow by having the diaphragm engage a seat member within the valve body. A depression member disposed in the valve body biases the diaphragm into the second position. A preferred depression member has an annular base with eight radial projections that extend inwardly from the base and that curve at resilient portions to dispose the projections at an angle relative to the base. In some embodiments, the valve body has a sealing surface where two portions of the valve body join, and the base member is supported adjacent to the sealing surface so as to be held by the joining of the two valve body members, so that the depression member is supported within the valve body without a fixed engagement to the diaphragm. In each embodiment the radial projections of the depression member have a resilient portion that resiliently bends to allow the radial projection to assume a deflected position and a depressed position with the depressed position biasing the diaphragm into the second position that inhibits flow through the valve. Preferably, the resilient portion defines a pivot point about which the resilient portion or the radial portion pivots when transitioning between the deflected and depressed positions.

DETAILED DESCRIPTION

Shown inFIG. 1is an illustrative embodiment of a preferred control valve10. The valve10includes a valve body12through which fluid can flow in a controlled manner. More specifically, the control valve10provides a diaphragm-type hydraulic control valve for preferably controlling the release and mixture of a first fluid volume having a first fluid pressure, such as for example a water main, with a second fluid volume at a second fluid pressure, such as for example, compressed gas contained in a network of pipes. Accordingly, the control valve10can provide fluid control between fluids or various media including liquids, gasses or combinations thereof.

The control valve10is preferably configured for installation in a piping manifold or other piping assembly to separate and control fluid flow between the first fluid volume and the second fluid volume. The control valve10includes a valve body12preferably constructed in two parts: (i) a cover portion12aand (ii) a lower body portion12b. “Lower body” is used herein as a matter of reference to a portion of the valve body12coupled to the cover portion12awhen the control valve is fully assembled. Preferably, the valve body12and more specifically, the lower body portion12bincludes an inlet14and outlet16. Each of the inlet and outlet14,16of the body12includes an appropriate end fitting for coupling to the manifold. Thus, the inlet14preferably includes a flanged end for coupling to a first fluid supply line, such as for example a water main, and the outlet16also preferably includes a flanged end for coupling to another pipe fitting such as, for example, a discharge pipe coupled to a network of interconnected pipes. The control valve10can be installed in either a horizontal orientation such that fluid entering the inlet14at one elevation is discharged from the outlet16at the same elevation, or alternatively, the control valve can be installed in a vertical orientation such that fluid entering the inlet at one elevation is discharged from the outlet at a different elevation.

The inlet14, outlet16and valve body12can be sized so as to provide a range of nominal valve sizes for coupling to corresponding pipe size. Preferably, the inlet14, outlet16and valve body12define nominal valve sizes of 1 inch and larger and more specifically nominal valve sizes of 1½ inch, 2 inch, 3 inch, 4 inch, 6 inch and 8 inch; however other nominal valve sizes can be provided. Preferably, the valve12, the cover12aand the lower valve body12bare separately cast and machined to provide the preferred openings and surface treatments such as threaded openings. However, other processes for construction and manufacturing can be used. The valve body12is preferably cast from ductile iron; however, other materials may be used provided they are suitable for a given fluid flow application.

The valve body12also includes a drain18for diverting the first fluid entering the valve10through the inlet14to outside the valve body. The valve body12further preferably includes an input opening20for introducing the second fluid into the body12for discharge out the outlet16. An exemplary cover12a, and lower body12bwith an inlet14, an outlet16, a fluid drain18and an input opening20, is shown and described in U.S. Pat. Nos. 6,095,484 and 7,059,578. However, unlike the valves shown and described in U.S. Pat. Nos. 6,095,484 and 7,059,578, the preferred diaphragm-type control valve10further includes a valve body12with a port22. The inclusion of a port22in the valve body12can provide means for an alarm system monitoring the valve for any undesired fluid communication from and/or between the inlet14and the outlet16. For example, the port22can be used for providing an alarm port to the valve10so that individuals can be alerted as to any gas or liquid leak from the valve body12. More specifically, the port22can be coupled to a flow meter and alarm arrangement to detect the fluid or gas leak in the valve body. In addition, the port22is preferably open to atmosphere and in communication with an intermediate chamber disposed between the inlet14and the outlet16. Each of the fluid drain18, input opening20and port22can include an appropriately threaded opening or other mechanical fastening member for coupling an appropriate pipe fitting or nipple to the given orifice.

Shown inFIG. 2is an exploded view of the preferred valve10showing the internal components of the valve10. The cover12aand the lower body portion12bare preferably coupled together by a plurality of bolts distributed in a bolt pattern about the body12. Shown inFIG. 2Bis a plan view of the control valve10and a preferred bolt pattern that includes eight nut and bolt assemblies. In an alternative bolt assembly, shown for example inFIG. 2C, a threaded stud nut and assembly50can be utilized. The stud assembly50preferably includes a threaded stud52engaged with the corner bolt holes of the cover12aand the lower valve body12b. To secure the cover12ato the assembly, the washer56and nut54can be threaded onto and tightened about the stud52. The stud assembly50can facilitate the assembly of the control valve10when installed in the vertical orientation. More specifically, preferably four threaded studs52can be equally spaced about the bolt pattern engaged with the lower valve body12b. The studs can be permanently or temporarily fixed to the lower valve body12b. The cover12acan then be disposed over the threaded studs52and permitted to hang supported by the threaded studs52thereby freeing an assembler's hands to complete the control valve assembly with the necessary threaded bolt and nut assemblies. Preferably, each of the threaded studs52are preferably rated to support a transverse load of between fifty to one hundred pounds (50-100 lbs.). To further facilitate assembly of the control valve10, the cover12acan include one or more eyelets to which a hook and cable or chain may be secured for lifting the cover12ainto position adjacent the lower valve body12b.

The cover12aand the lower body12beach include an inner surface such that, when the cover and lower body portion12a,12bare joined together, the inner surfaces further define a chamber24. The chamber24, being in communication with the inlet14and the outlet16, further defines a passageway through which a fluid, such as water, can flow. Disposed within the chamber24is a flexible preferably elastomeric member100for controlling the flow of fluid through the valve body12. The elastomeric member100is more preferably a diaphragm member configured for providing selective communication between the inlet14and the outlet16. Accordingly, the diaphragm member100has at least two positions within the chamber24: a lower most fully closed or sealing position and an upper most or fully open position. As shown inFIG. 2, disposed within the chamber24is a resilient depression member150positioned to bias the elastomeric member100into the closed and sealing position.

In the lower most closed or sealing position, as seen for example inFIG. 2A, the diaphragm100engages a seat member26constructed or formed as an internal rib or middle flange within the inner surface of the valve body12thereby sealing off communication between the inlet14and the outlet16. With the diaphragm100in the closed position, the diaphragm100preferably dissects the chamber24into at least three regions or sub-chambers24a,24band24c. More specifically formed with the diaphragm member100in the closed position is a first fluid supply or inlet chamber24ain communication with the inlet14, a second fluid supply or outlet chamber24bin communication with the outlet16and a diaphragm chamber24c. The cover12apreferably includes a central opening13for introducing an equalizing fluid into the diaphragm chamber24cto urge and hold the diaphragm member100in the closed position. Preferably, the equalizing fluid is provided from the first fluid source such that any surges in flow or pressure experienced at the inlet chamber24aare also experienced in the diaphragm chamber24csuch that the diaphragm chamber can react and compensate with a diaphragm pressure to maintain the diaphragm member100in the closed position.

Moreover, the preferred relative orientation of the sub-chambers24a,24b,24cis such that each of the inlet and outlet chambers24a,24bare adjacent the diaphragm chamber24cwhich, in combination with the flexibility of the diaphragm member100, contributes to the ability of the diaphragm chamber24cto compensate for surges in the flow or pressure experienced in either the inlet or outlet chambers24a,24b. In addition, the preferred orientation can further facilitate the performance of the valve10to maintain the sealed engagement of the diaphragm member100under the preferred ratio of equalizing fluid pressure to primary fluid pressure in a manner described in greater detail below. Known fluid control valves that use either a more rigid type of diaphragm or a mechanical latching clapper are believed to require an increased mechanical force or equalizing pressure to maintain a seal within the valve in order to compensate for any possible surges or fluctuations in the fluid being conveyed.

In operation of the control valve10, the equalizing fluid can be relieved from the diaphragm chamber24cin preferably a controlled manner to urge the diaphragm member100to the fully open or actuated position, in which the diaphragm member100is spaced from the seat member26thereby permitting the flow of fluid between the inlet14and the outlet16. The fluid release from the diaphragm chamber24ccan be regulated by way of, for example, an electrically controlled solenoid valve, such that the diaphragm member100can achieve regulated positions between the fully closed position and the fully open position. Accordingly, the diaphragm member100is preferably electrically actuated between the open and closed positions. Alternatively, the diaphragm can be actuated, regulated and/or closed or latched by other mechanisms such as, for example, a mechanical latching mechanism.

Shown inFIGS. 3A-3Dis an illustrative embodiment of the diaphragm member100. The diaphragm member100preferably defines a central axis A-A, and includes an upper surface102and a lower surface104preferably circumscribed by a flange portion101having a bolt pattern for being compressed and secured between the cover12aand lower valve body12b. Each of the upper and lower surface areas102,104are generally sufficient in size to seal off communication of the inlet and outlet chamber24a,24bfrom the diaphragm chamber24c. The upper and lower surface areas102,104are preferably substantially circular in plan view; however, other geometries are possible depending on the geometry of the chamber24and provided that the surfaces effectively dissect and seal the chamber24. The upper surface102of the diaphragm member is preferably smooth.

In its closed position, the lower surface104of the diaphragm member100preferably defines a centralized bulged portion110to avoid excessive stretching of the diaphragm material during diaphragm cycling and to enhance stability in both the upper and lower positions. The lower surface104thus preferably presents a substantially convex surface, and more preferably a spherical convex surface, with respect to the seat member26, having an area A1, and the upper surface102presents a substantially concave surface, and more preferably a spherically concave surface with respect to the diaphragm chamber24c, having an area A2. Upper surface A2is preferably about equal to A1. Portions of the lower surface104act to seal off fluid communication from the other chambers, i.e. a portion of lower surface104seals the inlet chamber24afrom the outlet chamber24band the diaphragm chamber24c. Accordingly, substantially convex surfaces are preferably presented to seal off the inlet and outlet chambers24aand24b. Moreover, the preferred geometry of the sub-chambers24a,24b,24crelative to one another preferably provides that the areas sealing the inlet and outlet chambers24a,24bare about equal, and that the inlet chamber24ais sealed off by a portion of the lower surface104having an area of about ½ A1, and the outlet chamber is sealed off by a portion of the lower surface104having an area of about ½ A1. In one preferred embodiment of the diaphragm100, the lower surface104defines a first radius of curvature and the upper surface102defines a second radius of curvature. Where the diaphragm100includes a middle layer103, the middle layer can further define a third radius of curvature. The various radii of curvature can be measured from a common central point or alternatively from different center points. The ratio of the radius of curvature of a lower layer to the radius of curvature of an upper layer is preferably greater than 1 and sufficient to permit the lower surface104to engage the seat member26when the diaphragm100is in the lower position to adequately seal off the inlet and outlet chambers24a,24b. Alternatively or in addition, the lower surface104can further define more than one radius of curvature such that the lower surface104engages the seat member26in a sealing manner.

In one preferred embodiment of the diaphragm member100for use in a valve body having a nominal valve size of four inches (4 in.), the middle layer defines a radius of curvature of about 7.75 inches to about eight inches (8 in.) and is preferably about 7.95 inches. As used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from context, all numerical values provided herein are modified by the term about. The upper surface102preferably defines a radius of curvature of about 7.5 inches to about 7.75 inches and is preferably about 7.6 inches. Each of the radii of curvature for the middle layer103and the upper surface102is preferably measured from a common central point along the central axis A-A of diaphragm member100. Thus, the ratio of the radii of curvature of the middle layer103to the upper surface102in a preferred four inch (4 in.) valve is about 1.05:1. In addition, the lower surface104preferably defines at least one radius of curvature ranging from about 4.25 inches to about 4.5 inches and is preferably about 4.33 inches measured from a center point off-set from the central axis A-A of the diaphragm member100. More preferably, the center point is horizontally off-set from the central axis by about 1.4. Moreover, the bulged portion110preferably defines a diameter ranging from about 10.10 inches to about 11.10 inches and is preferably about 10.47 inches.

In one preferred embodiment of the diaphragm member100for use in a valve body having a nominal valve size of six inches (6 in.), the middle layer103defines a radius of curvature of about 8.5 inches to about 9 inches and is preferably about 8.78 inches and even more preferably about 9.06 inches. The upper surface102preferably defines a radius of curvature of about 8.25 inches to about 8.75 inches and is preferably about 8.58 inches. Each of the radii of curvature for the middle layer103and the upper surface102is preferably measured from a common central point along the central axis A-A of diaphragm member100. Thus, the ratio of the radii of curvature of the middle layer103to the upper surface102in a preferred six inch (6 in.) valve is about 1.03:1. In addition, the lower surface104preferably defines at least one radius of curvature ranging from about 5.25 inches to about 5.5 inches and is preferably about 5.3 inches measured from a center point off-set from the central axis A-A of the diaphragm member100. More preferably, the center point is horizontally off-set from the central axis by about 1.6 inches. Moreover, the bulged portion110preferably defines a diameter ranging from about 12.45 inches to about 13.75 inches and is preferably about 12.9 inches. The preferred diaphragm member100is configured to engage and cooperate with the inner surfaces of the cover12aand lower body12bto define the three chambers24a,24b,24cin an orientation that can provide for a diaphragm chamber24cthat can effectively compensate for fluctuation and/or surges in fluid pressure in either one of the inlet and outlet chambers24a,24b.

The lower surface104of the diaphragm member100, as seen more specifically inFIG. 3B, preferably includes one or more support pads or elements112for supporting the diaphragm member100when the diaphragm cycles between the open and closed positions within the chamber24. More specifically, the support pads112are configured to engage a portion of the inner surface of the lower valve body12bto support the diaphragm100.

The lower surface104of the diaphragm member further preferably includes a pair of elongated sealing elements or projections114a,114bto form a sealed engagement with the seat member26of the valve body12. The sealing elements114a,114bpreferably extend in a parallel fashion along the lower surface104for a length about equivalent to the maximum arc length defined by the surface104. Each of the elongated sealing elements114a,114bpreferably tapers narrowly in cross-section (perpendicular to the axis of elongation) having a first angled surface116aand a second angled surface116beach extending from or contiguous with the lower surface104, as seen for example inFIG. 3C. Alternatively, the sealing elements114a,114bcan define any cross-sectional geometry provided the sealing element provides the sealing function provided herein. The first angled surface116apreferably defines an included angle α with a line parallel to the central axis A-A of about forty-five degrees. The second angled surface116bpreferably defines an included angle β with a line parallel to the central axis A-A of about fifteen degrees. Disposed between the first and second angled surfaces116a,116bis a terminal surface116cto terminate the sealing element and thereby define the height of the projection. Preferably, the terminal surface116cdefines a surface having one or more radii of curvature over its length from the first angled surface to the second angled surface. More preferably, the terminal surface116cdefines a peak of the sealing element having at least one radius of curvature.

The sealing elements114a,114bare preferably spaced apart so as to define a void or channel118therebetween. The parallel first angled surfaces116aof the sealing elements114a,114balong with a portion of the lower surface104disposed therebetween further define the sidewalls of the void or channel118and its channel height. The sealing elements114a,114bare configured to engage the seat member26of the valve body12when the diaphragm is in the closed position so as to seal off communication between the inlet14and the outlet16and more specifically seal off communication between the inlet chamber24aand the outlet chamber24b. Furthermore, the sealing members114a,114bengage the seat member such that the channel118cooperates with the seat member26to form an intermediate chamber24dto axially space the inlet chamber24aand the outlet chamber24bin a manner described in greater detail herein below. The lower surface104of the diaphragm can include more than two sealing elements114a,114bprovided that the additional sealing elements cooperate with the seat member26in a sealing fashion and allow for the formation of the intermediate chamber. Moreover, the lower surface104can be formed or constructed with any other surface formation, such as a convolution, provided that the formation can effectively form a sealed engagement with the seat member26and further provide for the channel118to facilitate formation of the intermediate chamber24d.

The material to be used for manufacturing the diaphragm100is dependent on the type of fluid being carried and on the temperature range to which the diaphragm is to be exposed. Preferably, the upper and lower surfaces102,104of the diaphragm100are constructed from layers of natural rubber material having a durometer hardness or shore value of about seventy-five (75) and further a pressure rating of about 2560 pounds per square inch (2560 psi.). Suitable materials for use at the upper and lower surfaces102,104include, for example, nitrile butadiene rubber and neoprene. Materials that can be used for reinforcements between the upper and lower surface layers at middle layer103of the diaphragm100include, for example, cotton and nylon and more preferably, nylon no. 2 reinforced material.

Shown inFIGS. 4A-4Bare two illustrative embodiments of the depression member150. The depression member150preferably includes an annular base portion152and radial projections154that extend inwardly from the base portion152about the central axis A-A. The annular base portion152preferably has an inner surface152afacing the central axis A-A from which the radial projections154extend, and an outer perimeter152bthat is disposed in a plane156that is preferably perpendicular to the central axis A-A. The radial projections154preferably extend inwardly from the inner surface152atowards each other. In the illustrations of the preferred embodiments, eight radial projections are distributed equidistantly on the inner surface152aabout the central axis A-A.

The radial projections154preferably have an arcuate portion154athat has a curvature and opposing ends, with a mounting end154bof each radial projection facing the annular base portion152and an opposing free end154cfacing the central axis A-A. The arcuate portion connects to the annular base portion via a resilient portion154dthat extends between the arcuate portion154aand the base portion152. The resilient portion154dextends from the annular base portion152towards the central axis A-A and provides a bend that disposes the arcuate portion154aat an angle relative to the plane156defined by the annular base portion152. In an alternative embodiment, the free end154ccan be a curled end where the arcuate portion curls back on itself to assist with the sliding of the arcuate portion over the upper surface102of the diaphragm. Furthermore, the upper surface102of the diaphragm can include ridges or projections disposed to sit on each side of the arcuate portion154ato receive each arcuate portion154aand to guide the arcuate portion154ato follow a path between pairs of ridges or projections when the arcuate portion slides over the upper surface102of the diaphragm.

Preferably, the resilient portion154dis a resilient bend in the radial projection154that provides an angulation to the radial projection, to define a depression angle158of the depression member150between the mounting end154band the annular base portion152. The depression angle158can be taken from various points along the length of the resilient portion154dor from various points on the annular base portion152or the arcuate portion154a, and is preferably taken at comparable points that are directly opposed to each other about the resilient portion154d, and is most preferably taken at the points where the resilient portion154dengages or transitions into the annular base portion152or the arcuate portion154a. The resilient portion154dis preferably resilient and can be reversibly deformed by the application of an external force to store energy in the resilient portion154dand temporarily change the depression angle158from one angle to another angle. Preferably, the external force compresses the depression member150in a direction parallel to the central axis A-A to bring the arcuate portions154acloser together and to change the depression angle158to a smaller angle. The stored energy is preferably released as an expanding force when the depression member150returns or attempts to return to its original angulation. The arcuate portions154aare cantilevered from the resilient portion154das each extends from the resilient portion154dtowards the central axis A-A. When the stored energy in the resilient portion154dis being released, the force is distributed along the lengths of the cantilevered arcuate portions154aand the cantilever can be configured to control how the force is distributed. The resilient bend of the resilient portion154d, and the movement of the arcuate portion154aand the resilient portion154dabout the bend of the resilient portion154c, define a pivot point159about which the resilient portion154dand/or the arcuate portion154apivot when the depression member150is loaded with an external force. Depending on the shape of the resilient bend, the pivot point159can be disposed at a position that is internal or external to the depression member150or within the mass of the resilient portion154citself. Preferably the pivot point159is at a radial distance from the central axis A-A that is less than the radial distance of the inner surface152afrom the central axis A-A.

The shape and configuration of the resilient portion154dcan vary to provide different properties for the depression member150, to manipulate the position of the pivot point159, and to vary how applied external forces are stored or released by the resilient portion154dor the arcuate portion154a. For example, as illustrated inFIG. 4A, the resilient portion154dcan initially extend from the base portion152along the plane156and then present a single bend that angles the arcuate portion154arelative to the plane156. In another example, illustrated inFIG. 4B, the resilient portion154dcan initially extend from the base portion152along the plane156and then present two bends with the first bend angled away from the arcuate portions154awhich leads to a second bend angled toward the arcuate portions154a. As also illustrated inFIG. 4B, the two bends can be characterized as an undulation. In another alternative, instead of a bend, the resilient portion can be formed from separate components that are joined together to form the radial projections, such as a separate arcuate portion154aand resilient portion154dthat are laid next to each other at mating ends and then joined with a weld, crimp, or band that holds the arcuate portion154aand resilient portion154dtogether to form a composite resilient portion. Also, as illustrated inFIGS. 4A-4B, the resilient portion154dengages the base portion152with insets153that are stress-relieving scalloped areas disposed at corners formed between surfaces of the resilient and base portions.

The resilient portion can also be formed to provide a smooth curve that reacts linearly as the external force applied to the depression member is increased, or to have a variable profile with, for example, zig-zags that provide a non-linear reaction. In a further example, the resilient portion can have a profile that is a waveform that increases or decreases in frequency as the resilient portion comes into engagement with the first and second ends so as to provide a varying response of the depression member as the external load increases; for example, a resilient portion with a waveform profile can be configured to become stiffer as an external load increases. The resilient portion can also have multiple bends that allow the resilient portion to store energy from an external force at several points along a length of the resilient portion or arcuate portion so as to distribute such loads over a larger area, or have bends that focus the energy at predetermined points on the resilient portion. The shape of the resilient portion can be modified to position the pivot point159at a location within the profile of the depression member150, or modified to provide multiple pivot points as the external force increases or modified to provide a pivot point that moves as the external force increases. The shape of the resilient portion154dcan also be modified to vary how forces are distributed between the resilient portion154dand the mounting and free ends154b,154c. For example, the width of the resilient portion can be increased to provide a stiffer connection where the resilient portion154dengages the mounting ends154bas compared to a more remote portion of the arcuate portion that has a narrower profile. In another example, the width of the arcuate portion154acan be varied along its length to provide the mounting and free ends with varying stiffness.

The sealing elements114a,114bof the diaphragm member100are configured to form a sealed engagement with the seat member26of the valve body12. Shown inFIGS. 5A-5Dare detailed views of the preferred lower valve body portion12bof the control valve10. The lower control valve body12bpreferably defines a first valve axis IVC-IVC. The inlet and outlet14,16of the control body are preferably centered about, coaxial with and spaced apart along the first valve axis IVC-IVC. Further centered along, spaced apart and substantially orthogonal to the first axis IVC-IVC are the fluid drain pipe18and the input opening20each respectively in communication with the fluid supply chamber24aand the pressurized gas supply chamber24b. Also extending along the first axis IVC-IVC are brace or support members28a,28b. The support members28a,28bare preferably aligned for engagement with the support pads112disposed or formed on the lower surface104of the diaphragm member100. The support members28a,28bpreferably extend from the flanges of the inlet and outlet14,16to intersect the support member26. The support members28a,28bpreferably form a unitary construction with the support member26and the rest of the lower valve body12bor, alternatively, the support members28a,28bcan be joined to the support member26and the body12by other joining techniques such as, for example, welding.

The lower control valve body12bfurther preferably defines a second axis IVD-IVD which is substantially orthogonal to the first axis IVC-IVC. Preferably aligned with the second axis IVD-IVD is the seat member26extending the width of the valve body12so as to effectively divide the chamber24in the lower valve body12into the preferably spaced apart and preferably equal sized sub-chambers of the inlet chamber24aand the outlet chamber24b. Moreover, the elongation of the seat member26preferably defines a curvilinear surface or arc having an arc length to mirror the convex surface of the lower surface104of the diaphragm100. Further extending along the preferred arc length of the seat member26is a groove30constructed or formed in the surface of the seat member26. The groove30preferably extends the full length of the seat member26so as to extend the width of the lower valve body12b. Furthermore, the groove30preferably tapers narrowly at its ends. In addition, the walls of the seat member26that define the groove30are preferably parallel. Alternatively, the groove30can be formed such that the walls forming the groove30are angled relative to one another, another reference line or other surface in the valve body12. The portion of the seat surface26defining the bottom of the groove30preferably forms a semi-circular arc in the plane perpendicular to the direction of elongation for the groove30. Other geometries are possible provided the channel30delivers the desired fluid and pneumatic characteristics described herein. Moreover, the depth of the groove30can vary along its length such that the groove30is preferably deepest at its center and becomes more shallow toward its lateral ends. The groove30further bisects the engagement surface of the seat member26preferably evenly along the seat member length. With the support pads112of the diaphragm member100aligned to engage the support members28a,28bwhen the diaphragm member100is in the closed positioned, the elongated sealing members114a,114bare preferably aligned to engage the bisected surface of the seat member26. Engagement of the sealing members114a,114bwith the engagement surfaces26a,26bof the seat member26further places the channel118of the diaphragm100in communication with the groove30.

Shown inFIG. 5Bis a detailed view of the seat member26and its intersection with the support members28a,28b. Preferably, the engagement surfaces26a,26bof the seat member26are substantially planar, and the width of the engagement further preferably widens in a direction from the center of the engagement seat26to the lateral ends of the seat member26. Generally, the surfaces26a,26bare configured sufficiently wide over their entire length so as to maintain sealing contact with the sealing elements114a,114b. Moreover, the surfaces26a,26bare configured wide enough so as to maintain sealing contact with the sealing elements114a,114bregardless of any movement of the sealing elements114a,114balong the longitudinal axis IVC-IVC. Accordingly, the surfaces26a,26bcan maintain sealed engagement with the sealing elements114a,114bdespite changes in fluid pressure in either the inlet or outlet chamber24a,24bwhich can impose forces on the diaphragm100and sealing elements114a,114bin a direction along the axis IVC-IVC.

The seat member26is preferably formed with a central base member32that further separates and preferably spaces the inlet and outlet chambers24a,24band diverts fluid in a direction between the diaphragm100and the seat member engagement surfaces26a,26b. As seen, for example, inFIGS. 5C and 5D, the base member32is preferably broader in the direction along the first axis IVC-IVC than along the second axis IVD-IVD. The base member32is preferably substantially aligned with the central axis B-B of the valve body12which substantially orthogonally intersects the plane formed by the intersection of the first axis IVC-IVC and the second axis IVD-IVD. Preferably formed in the base member32between the drain18and the input opening20is the port22.

The port22is preferably constructed as an alarm port from one or more voids formed in the base member32. Preferably, the port22includes a first cylindrical portion22aformed in the base member32. The first cylindrical portion22apreferably defines a central axis off-set or spaced from the central axis B-B of the lower valve body12. The first cylindrical portion22ais further preferably wider in the direction along the first axis IVC-IVC than in the direction along the second axis IVD-IVD. Accordingly, the first cylindrical portion22ais preferably oblong in cross-section.

Axially in communication with the first cylindrical portion22ais a second cylindrical portion22bformed in the base member32. The second cylindrical portion22bis preferably wider in the direction along the second axis IVD-IVD than in the direction along the first axis IVC-IVC. Accordingly, the second cylindrical portion22bis oblong in cross-section and preferably elongated in a direction substantially orthogonal to the direction of elongation of the first cylindrical portion22a. The second cylindrical portion22bpreferably defines a central axis preferably aligned with the central axis B-B of the lower valve body12. Moreover, the second cylindrical portion22bpreferably axially extends along the central axis B-B so as to intersect and be in communication with the groove30. Accordingly, the port22preferably intersects and is in communication with the groove30and, when the diaphragm member100is in the closed position, the port22is further preferably in sealed communication with the channel118formed in the diaphragm member100.

The communication between the diaphragm channel118, the groove30and the port22is preferably bound by the sealed engagement of the sealing elements114a,114bwith the seat member surfaces26a,26b, to thereby define a preferred fourth chamber, intermediate chamber24d, as seen, for example, inFIG. 2A. The intermediate chamber24dis preferably open to atmosphere thereby further defining a fluid seat, preferably an air seat to separate the inlet and outlet chambers24a,24b. The inventors have discovered that providing an air seat between the inlet and outlet chambers24a,24ballows each of the inlet and outlet chambers to be filled and pressurized while avoiding failure of the sealed engagement between the sealing element114and the seat member26. Each sealing element114is acted upon by a fluid force on only one side of the element and preferably atmospheric pressure on the other, the fluid pressure in the diaphragm chamber24cbeing effective to maintain the sealed engagement between the sealing elements114and the seat member26during pressurization of the inlet and outlet chambers24a,24b. Accordingly, the preferred diaphragm-type valve10can eliminate the need for a check valve downstream of the control valve, unlike, for example, the installations of the preaction fire protection systems shown and described in U.S. Provisional Patent Application No. 60/887,040. Moreover, the preferred control valve10and the preferred intermediate chamber24dexposed to atmosphere can comply with the installation and/or operational requirements such as for example, FM Standard 1020, by providing a port for drainage or an alarm.

The ability to pressurize both the inlet and the outlet chambers24a,24bis particularly useful where it is desirable to control release of a primary fluid such as, for example, water, into a normally closed system while providing and maintaining the system with a pressurized secondary fluid such as, for example, compressed air. For example, the control valve10can be installed and operated in a liquid/gas manifold in the following manner. The control valve10is disposed between the primary fluid source, such as for example, a water main and the secondary fluid source, such as for example, a compressed air feed or a source of compressed nitrogen gas. More specifically, as schematically shown, for example, inFIG. 6, the control valve10is preferably coupled to the primary fluid main at the inlet14. The fluid drain18is preferably closed off by connection of an appropriate shut-off piping element such as, for example, a manual-shut off valve. The secondary fluid or compressed gas source is coupled to the input opening20, and the outlet16is preferably coupled to the system to be filled and pressurized by the compressed gas.

The control valve10and the manifold can be placed into service by preferably bringing the valve10to the normally closed position and subsequently bringing the inlet chamber24aand the outlet chamber24bto operating pressure. In one preferred installation, the primary fluid source is initially isolated from the inlet chamber24aby way of a shut-off control valve such as, for example, a manual control valve located upstream from the inlet14. The secondary fluid source is preferably initially isolated from the outlet chamber24bby way of a shut-off control valve located upstream from the input opening20. An equalizing fluid, such as water from the primary fluid source, is then preferably introduced into the diaphragm chamber24cthrough the central opening13in the cover12a. Fluid is continuously introduced into the chamber24cuntil the fluid exerts enough pressure P1to bring the diaphragm member100to the closed position in which the lower surface104engages the seat member26and the sealing elements114a,114bform a sealed engagement about the seat member26.

With the diaphragm member100in the closed position, the inlet and outlet chambers24a,24bcan be pressurized respectively by the primary and secondary fluids. More specifically, the shut-off valve isolating the primary fluid can be opened so as to introduce fluid through the inlet14and into the inlet chamber24ato preferably achieve a static pressure P2. The shut-off valve isolating the compressed gas can be opened to introduce the secondary fluid through the input opening20to pressurize the outlet chamber24band the normally closed system coupled to the outlet16of the control valve10to achieve a static pressure P3.

As described above, the presence of the intermediate chamber24d, which is normally open to atmosphere, separating the inlet and outlet chambers24a,24bmaintains the primary fluid pressure P2to one side of the sealing member114aand the secondary fluid pressure P3to one side of the other sealing member114b. Thus, diaphragm member100and its sealing members114a,114bare configured so as to maintain the sealed engagement with the seat member26under the influence of the diaphragm chamber pressure P1. Accordingly, the upper and lower diaphragm surface areas A1, A2, and A3are preferably sized such that the pressure P1is large enough to provide a closing force on the upper surface of the diaphragm member100so as to overcome the primary and secondary fluid pressures P2, P3urging the diaphragm member100to the open position. However, preferably the ratio of the diaphragm pressure to either the primary fluid pressure P1:P2or the secondary fluid pressure P1:P3is minimized such that the valve10maintains a fast opening response, i.e. a low trip ratio, to release fluid from the inlet chamber when needed. More preferably, every 1 psi of diaphragm pressure P1is at least effective to seal about 1.2 psi of primary fluid pressure P2. This is an advantage over known diaphragm valves that are believed to require a 1:2.5 pressure ratio of diaphragm pressure to primary fluid pressure because, in such known valves, the chambers are oriented such that the diaphragm pressure is directed completely in the normal direction to the diaphragm seat and the incoming fluid. Known mechanical latching deluge valves also are believed to require a 1:2.5 ratio because of similar chamber orientation and the need for a mechanical latch or linkage. Because the preferred control valve10can use a lower diaphragm pressure P1to primary fluid pressure P2, the valve10can be constructed smaller than the known control valves of similar nominal valve size. Moreover, the low pressure ratio, in combination with the chamber orientation and flexible diaphragm, provides for the preferred control valve10that is capable of providing effective surge control or resistance to minimizing or more preferably eliminating false trips.

To actuate the valve10, fluid is preferably released from the diaphragm chamber24cat a faster rate than it can be replenished into the chamber24c. For example, a solenoid control valve coupled to the chamber inlet13can be electrically actuated to release fluid from the diaphragm chamber24c. The loss of pressure on the upper surface102of the diaphragm member100permits the fluid pressure in the adjacent fluid supply chamber24ato urge the diaphragm member to the open position spaced from the seat member26. Fluid is permitted to flow past the support members28a,28b(support members28a,28bnot shown inFIG. 6for clarity) to displace the compressed gas in the outlet chamber24bfor discharge out the outlet16and into the system coupled to the control valve10. Fluid is further permitted to fill the groove30and flow out the alarm port22. With an appropriate flow alarm coupled to the port22, fluid flow can be detected and appropriate personnel can be notified of the operation of the valve10.

Accordingly, the control valve10can be installed in a preaction fire protection system with its outlet16in communication with a riser pipe that is coupled to a network of sprinklers interconnected by pipes and pressurized by the compressed gas or air. More specifically, the control valve10can be installed in any one of the preaction fire protection systems shown and described in U.S. Provisional Patent Application No. 60/887,040 without the need for a check valve located downstream of the valve10. Schematically shown inFIG. 7is the preferred control valve10installed in a preaction fire protection system200. In addition to the control valve10, the preaction system200includes a piping network of one or more fire protection devices such as, for example, fire protection sprinklers210distributed along a feed main215in accordance with one or more fire sprinkler installation standards, such as for example, National Fire Protection Association (NFPA) publication, “NFPA 13: Standard for the Installation of Sprinkler Systems” (2007).

In accordance with the preferred installation described above, the control valve10is installed in the fire protection system with its outlet coupled to the network of sprinklers210and feed main by a riser pipe220. A compressed gas or air source225is placed in controlled communication with the input opening20for pressurizing the network of sprinklers with supervisory air or gas preferably ranging from about 8-12 psi. and more preferably about 10 psi. Alternatively, the preferred control valve10can be installed in a deluge fire protection system in which the network of sprinklers is open to atmosphere. The inlet14of the control valve10is preferably placed in controlled communication with a preferred liquid supply source such as, for example, a water main230. Accordingly, the control valve10is installed such that the “wet” or liquid portion of the system is at the inlet side of the valve10and the “dry” or gas portion of the system is on the outlet side of the valve10. The control valve10and the system200can be placed into service in a manner as described above such that the diaphragm member100provides controlled sealed communication between the water main230and the network of sprinklers210. Moreover, the diaphragm can be brought to the sealed position by the introduction of the fluid, preferably appropriately piped and trimmed from the fluid source230through an appropriate restriction233, into the diaphragm chamber24c, and each of the inlet and outlet chambers24a,24bcan be brought to pressure by respective introduction of water into the inlet14and compressed air into the outlet16. More preferably, the diaphragm100is held in its sealed position with the inlet chamber24aunder static pressure from the water such that the sealing pressure and the static water pressure define the preferred ratio of P1:P2substantially equal to about 1:1.2. Because the preferred control valve10, upon seating in the sealed position, forms the intermediate chamber24dto act as an air seat, the outlet chamber24band the network of normally closed sprinklers define a closed system in the preaction system in which incoming compressed air can fill the riser220and the main feed215and provide supervisory air to the network of sprinklers at the preferred pressure without the use of a check valve anywhere downstream of the valve10. Accordingly, between the outlet chamber24bof the control valve10and the network of sprinklers210a single and preferably substantially constant air pressure can be defined equivalent to the supervisory air of the system200.

The system200can be configured for single or double interlock operation of the control valve10. Furthermore, the operation of the control valve10can be electrically, pneumatically, hydraulically actuated or a combination thereof. For example, the system200can be configured as a single interlock system having a detector235afor detection of heat or smoke to send a detection signal, preferably through a control panel240, to a solenoid valve236, vented to atmosphere, that releases water from the diaphragm chamber24cfor actuation of the control valve10as discussed above. The detector235acan be any one of a heat sensitive thermostat, smoke detector or electric manual pull station. Alternatively, the system200can be configured as a single interlock system having a dry pilot for actuation of the control valve10. More specifically, the system200can include a dry pilot line245that is pneumatically pressurized having one or more pilot sprinklers250acting as heat detectors disposed along the line245. Upon actuation of the pilot sprinklers250in the presence of a fire, the release of pneumatic pressure can be configured to operate a dry pilot actuator255, vented to atmosphere, which can be coupled to the control valve10to release water from the diaphragm chamber24c. Further in the alternative, the pilot line can be configured as an appropriately installed wet pilot line pressurized with water and coupled to the diaphragm chamber24c. Actuation of the pilot sprinkler250in the presence of a fire releases water from the wet pilot line245and from the diaphragm chamber24cfor operation of the control valve10.

Any one of the above single interlock systems can be alternatively configured as a double interlock system. For example, the system200can be configured as a double interlock system having a detector235afor detection of heat or smoke to send a detection signal and a second detector235bfor detecting low air pressure in the network of sprinklers210. Each of the detectors235a,235bcan be coupled to a releasing panel in which actuation of each of the detectors is required to operate the releasing panel to release water from the diaphragm chamber24cand operate the control valve10. Alternatively, the system200can be configured as a double interlock system having a dry pilot and an electrical interlock for actuation of the control valve10. More specifically, the system200can include a dry pilot line245that is pneumatically pressurized having one or more pilot sprinklers250acting as heat detectors disposed along the line. Upon actuation of the pilot sprinklers250in the presence of a fire, the release of pneumatic pressure can be configured to operate a dry pilot actuator255. To operate the control valve10the system can incorporate the heat detector for energizing a solenoid valve that in series with the dry pilot actuator255operates the control valve10. In the alternative, the pilot line of the double interlock system can be configured as a wet pilot line pressurized with water and coupled to the diaphragm chamber24c. Any one of the above preaction systems preferably includes an alarm connected to the alarm port22of the control valve10in order to detect the flow of fluid upon actuation of the control valve10. Further in the alternative, the control valve10can be installed in a non-interlock preaction fire protection system.