Abstract:
A valve module for control of a fluid flow, especially flow of a fluid to be filtered in a filter apparatus. The valve module includes a valve ( 12 ) with a valve cover ( 14 ) a valve body ( 13 ) and a valve seat ( 15 ). The valve body mates with the valve seat ( 15 ), which is integrated in an adapter plate ( 11 ). The adapter plate ( 11 ) is provided with an inlet ( 27 ) and an outlet, with an unfiltered fluid channel ( 20 ) and a filtered fluid channel ( 22 ) arranged in the adapter plate. The integration of the valve seat ( 15 ) and unfiltered and filtered fluid channels ( 20, 22 ) in the adapter plate ( 11 ) makes possible a space-saving construction of the valve ( 12 ).

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation of international patent application no. PCT/EP2006/060253, filed Feb. 24, 2006 designating the United States of America and published in German on Aug. 31, 2006 as WO 2006/089945, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. DE 10 2005 008 923.2, filed Feb. 24, 2005. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates to a valve module and to a filter device incorporating such a valve module.  
         [0003]     Diaphragm valves, which are intended to control a fluid flow, are known. An example of diaphragm valves of this type is shown in  FIG. 5 . The following reference numerals relate to this figure. The diaphragm valve has a valve housing  101 , to which a diaphragm  103  is attached. A valve housing cover  102  is situated above the diaphragm  103 , which is connected to the diaphragm  103  to form a seal. An inlet  104  and an outlet  105  are situated in the valve housing  101 , the inlet  104  being separated from the outlet  105  by the diaphragm  103  to form a seal below a predefined pressure level. When the predefined pressure level is exceeded, the diaphragm  103  lifts off of a valve seat  106  situated on the valve housing  101 . The fluid may thus flow from the inlet  104  to the outlet  105 . The diaphragm valve is connected to fluid lines, which supply the fluid to the diaphragm valve and drain it therefrom. This diaphragm valve requires a relatively large amount of space, because the fluid is conducted through the valve housing  101 .  
       SUMMARY OF THE INVENTION  
       [0004]     The object of the present invention is to provide an improved diaphragm valve module.  
         [0005]     Another object of the invention is to provide a valve module which requires less overall space than prior designs.  
         [0006]     A further object of the invention is to provide a valve module which is cost-effective.  
         [0007]     These and other objects are achieved in accordance with the present invention by providing a valve module for controlling a fluid flow comprising a valve having a valve cover, a valve body, and a valve seat, in which the valve body is configured to matingly correspond to the valve seat; the valve seat is integrated in an adapter plate; the valve body and the valve cover are attached to the adapter plate in a sealed manner to form a control chamber; and the adapter plate has an unfiltered fluid channel and a filtered fluid channel situated inside the adapter plate, an inlet leading to the unfiltered fluid channel, and an outlet leading from the filtered fluid channel.  
         [0008]     The valve module according to the present invention is used for controlling a fluid flow, in particular a liquid flow to be filtered. The valve module comprises a valve having a valve cover, a valve body, and a valve seat. The valve body matingly engages the valve seat, which advantageously may be integrated in an adapter plate. The valve body and the valve cover are connected to the adapter plate, the adapter plate having an inlet and an outlet. An unfiltered fluid channel and a filtered fluid channel are situated inside the adapter plate. The valve body may have any desired configuration, e.g., as a ball or plate. Because the adapter plate forms the valve seat, a valve bottom part may be omitted. Overall space is thus saved on one hand, and guidance of the flow is simplified on the other hand, because the fluid flow is guided in the adapter plate in any case.  
         [0009]     In accordance with one advantageous embodiment of the invention, the valve seat is press-fit into the adapter plate. If desired, a different material may be selected for the valve seat than for the adapter plate. Furthermore, the valve seat may be machined on different machines than the adapter plate.  
         [0010]     In another advantageous embodiment of the invention, the valve body is a resilient or elastic diaphragm. It may comprise different areas. Preferably, the diaphragm has a boundary zone which is connected to the adapter plate, by which exact positioning of the diaphragm is achieved and slipping is prevented.  
         [0011]     It is advantageous if the adapter plate is provided with a valve in the area of the filtered fluid channel, with which the filtered fluid channel can be closed. The filtered fluid channel may thus be closed or opened as needed. This is advantageous when replacing attachment parts.  
         [0012]     In accordance with a further advantageous embodiment of the present invention, the adapter plate is provided with a valve in the area of the unfiltered fluid channel, with which the unfiltered fluid channel can be closed. Therefore, downstream components may be changed without any undesired discharge of fluid from the overall device.  
         [0013]     In one refinement of the present invention, the filtered fluid channel is provided with at least two valves arranged in parallel, which close or open two separate channels independently of one another. Therefore, only one single channel or all channels may have flow through them as needed. This is especially significant for the flow through components situated downstream.  
         [0014]     The filter device according to the present invention is used for filtering a fluid, in particular a processing fluid. Processing fluids in the sense of the present patent application include gases or liquids which are used, for example, to carry away chips or cuttings created during the machining of workpieces or the production of products. For example, the processing fluid may be an air stream or a coolant and/or lubricant, which carry away severed material from the workpiece and/or protect the tool. The filter device comprises a valve module as described above, a container, an unfiltered fluid connection, and a filtered fluid connection. At least one filter unit stack is arranged in the container and is connected to the valve module. The valves serve to individually activate or actuate the filter unit stacks. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]     The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments shown in the accompanying drawing figures, in which:  
         [0016]      FIG. 1  is a side elevation view of a filter device according to the present invention;  
         [0017]      FIG. 1   a  is a schematic view of a filter device according to the invention;  
         [0018]      FIG. 2  is a sectional view of an adapter plate for the valve of the invention;  
         [0019]      FIG. 3  is a sectional view of a valve in the filtered fluid channel taken along line A-A of  FIG. 2 ;  
         [0020]      FIG. 4  is a sectional view of a valve in the unfiltered fluid channel taken along line B-B of  FIG. 2 , and  
         [0021]      FIG. 5  is a sectional view of a prior art diaphragm valve. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0022]     A filter device is schematically illustrated in  FIG. 1 . The filter device comprises a valve module  10 , which is formed by an adapter plate  11  and valves  12 . The valves  12  each comprise a flexible elastic diaphragm  13  and a valve cover  14 . The diaphragm  13  and the valve cover  14  are attached to the adapter plate  11 . The diaphragm  13  contacts a valve seat  15 , which is integrated into the adapter plate, e.g., by constructing it in one piece with the adapter plate or by press-fitting it into the adapter plate. A filter unit stack  16 , which is composed of individual filter units as are known in the prior art, adjoins the adapter plate  11 . Multiple filter unit stacks  16  may also be arranged in parallel to increase the filter area. These multiple filter units produce a filter unit module  16   a . The filter units each comprise a filter medium, an unfiltered fluid channel, and a filtered fluid channel. The filter unit stack  16  is closed on the side situated opposite the adapter plate  11  by a clamping plate  17 . The entire unit composed of the valve module  10 , the filter unit stack  16 , and the clamping plate  17  is situated in a vessel or container  18 . The unfiltered fluid connection  19  opens into an unfiltered fluid channel  20  in the adapter plate  11 . The fluid to be filtered may be introduced into the filter device through the unfiltered fluid connection  19 . Furthermore, the adapter plate  11  comprises a filtered fluid channel  22 , which is connected to a collecting vessel  23 . The filtered fluid is discharged from the filter device. A part of the fluid is stored in the collecting vessel  23  until it is needed to backwash the filter units. A filtered fluid connection  21 , through which the fluid may be drawn out, may be provided for removing the filtered fluid. However, as an alternative, the collecting container  23  also may be exchanged when full.  
         [0023]     A filter bag  24 , which is situated in a drawer  25 , is situated below the container  18 . A concentrate drain  26 , which is closable by the valve  12  disposed in the unfiltered fluid channel  20 , discharges into the filter bag  24 .  
         [0024]     The fluid to be filtered flows through the unfiltered fluid connection  20  into the adapter plate  11 . The valve  12  in the unfiltered fluid channel  20  is closed, as a result of which the fluid flows through the filter unit stack  16 . The valves  12  in the filtered fluid channel  22  are opened, so that the filtered fluid flows through the filtered fluid channel  22  into the collecting vessel  23 .  
         [0025]     After a defined time interval, and/or as needed, the filter units of the filter unit stack  16  may be regenerated. For this purpose, the valve  12  in the filtered fluid channel  22  of the filter unit stack  16  which is to be cleaned is opened, and the valves  12  of the filter unit stacks  16  which are not to be regenerated are closed. The valve  12  in the unfiltered fluid channel  20  is opened. The filtered fluid impinges against the filter units and flows back through them in the opposite flow direction. The deposits on the inflow side of the filter unit are thus removed and flushed through the concentrate drain into the filter bag  24 . After this backwashing procedure, the valve  12  in the unfiltered fluid channel  20  closes again, and the filter device is again ready to filter unfiltered fluid.  
         [0026]     The valves  12  are activatable using a control fluid, in particular compressed air. The control fluid is introduced between the diaphragm  13  and the valve cover  14  with sufficient pressure that the diaphragm  13  is not lifted off from the valve seat  15  in normal operation. When the valve  12  is to be opened, the pressure of the control fluid is reduced and the diaphragm  13  thus lifts off from the valve seat  15 .  
         [0027]     A filter device according to  FIG. 1  is schematically illustrated in  FIG. 1   a . The filter device comprises a container  18 , in which a filter unit module  16   a  comprising four filter unit stacks  16  is situated. The filter unit module  16   a  has an unfiltered fluid connection  19 , which may be opened and closed using a valve  12   a . The unfiltered fluid connection  19  is connected to the unfiltered fluid channel  20 ′ of each filter unit stack  16 . The filtered fluid channels  22 ′ of the filter unit stacks  16  are connected to a filtered fluid channel  22 , with each filter unit stack  16  being able to be opened and closed using a separate valve  12   c.    
         [0028]     The filtered fluid channel  22  discharges on one hand into a collecting vessel  23  and on the other hand into a filtered fluid container  23 ′. The filtered fluid container  23 ′ can be shut off from the filtered fluid line  22  using a valve  12   d . The unfiltered fluid connection  19  is connected to an unfiltered fluid container R, and a pump P is provided to force the fluid to be filtered into the filter unit module  16   a . Furthermore, the unfiltered fluid connection  19  is connected to a concentrate drain  26 , which discharges into a filter bag  24 . The concentrate drain  26  may be opened and closed via a valve  12   b.    
         [0029]     The container  18  is provided with a drain line A which discharges into a further container  18 ′. The container  18 ′ is connected to an unfiltered fluid container R such that fluid collected in the container  18 ′ may be returned to the unfiltered fluid container R by opening the valve  12 ′.  
         [0030]     A sensor S 1  for detecting a minimum level status and a sensor S 2  for detecting a maximum level status are provided for detecting the liquid level in the container  18 ′. As soon as the liquid level is detected by the sensor S 2 , the valve  12 ′ is opened. After the level falls below sensor S 1 , the valve  12 ′ is closed again.  
         [0031]     The fluid to be filtered starts out in the unfiltered fluid container R. From there, it is pumped with valve  12   a  open through the unfiltered fluid connection  19  into the filter unit module  16   a . In this state, the valve  12   b  is closed. At least one of the valves  12   c  is open, so that the filtered fluid may exit from the filter unit module  16   a  through the filtered fluid channel  22 . The filtered fluid flows into the collecting vessel  23  or, with valve  12   d  open, into the filtered fluid container  23 ′, from where it is supplied for its further use.  
         [0032]     If one or more of the filter unit stacks  16  becomes loaded with dirt, the valve  12   d  is closed and the respective valve  12   c  is opened so that the filter unit stack  16   a  may be backwashed. For this purpose, the valve  12   a  is also closed and the valve  12   b  into the concentrate drain  26  is opened. The contaminated backwashing fluid is collected in the filter bag  24 . When the fluid contained in the filter unit module  16   a  may not be filtered further, the fluid is removed from the filter unit module via the concentrate drain  12   b . When the bag  24  is full, it is replaced or emptied. The concentrate is then disposed of. Because the filter units of the filter unit stack  16  are only clamped against one another, slight leaks may occur. These are collected in the container  18  and removed from the container  18  via the drain line A.  
         [0033]     A respective pressure switch D, which detects the pressure level in the particular channel, is situated both in the filtered fluid channel  22  and also in the unfiltered fluid channel  20 .  
         [0034]     An adapter plate  11  is illustrated in a sectional view in  FIG. 2 . Components in  FIG. 2  corresponding to those of  FIG. 1  are identified by the same reference numerals. The unfiltered fluid channel  20  in the adapter plate  11  is represented by two holes extending diagonally downward toward the middle, with one hole being closed to the outside. The other hole forms an inlet  27 , through which the fluid to be filtered is introduced into the adapter plate  11 . The unfiltered fluid channel  20  has distributor holes  28 , which are situated in such a way that they correspond to the filter unit stacks  16 . Furthermore, the number of the distributor holes  28  is matched to the number of the filter unit stacks  16  so that each filter unit stack  16  has its own distributor hole. The valve seat  15  for the valve  12  provided in the unfiltered fluid channel  20  is situated in the middle, where the two holes meet.  
         [0035]     The filtered fluid channel  22  also is formed by a bore hole, with a vertically extending bore hole meeting a horizontally extending bore hole. The filtered fluid exits again from the adapter plate  11  through the vertical hole. Openings  29 , whose number corresponds to the number of filter unit stacks  16 , are situated in the horizontally extending hole. A valve seat  15  for a valve  12  is situated in each of these openings  29 . Furthermore, the horizontally extending hole is closed on its front sides in operation.  
         [0036]      FIG. 3  shows a valve  12  in the filtered fluid channel  22  in a sectional view taken along line A-A of  FIG. 2 , and  FIG. 4  shows a valve  12  in the unfiltered fluid channel  20  in a sectional view taken along line B-B of  FIG. 2 . The construction of the valves  12  is identical in both figures. Again, components corresponding to  FIG. 1  or  FIG. 2  are identified by the same reference numerals. The diaphragm  13  and the valve cover  14  are connected to one another and to the adapter plate  11  in a sealed manner.  
         [0037]     A control chamber  30 , which is connected via a solenoid valve  31   a  to a control fluid line  31 , is formed between the diaphragm  13  and the valve cover  14 . A control fluid may be introduced into the control chamber  30  through the control fluid line  31  using the solenoid valve  31   a , such that the control pressure required in the control chamber  30  can be adapted to the particular operating state of the valve  12 . When the valve  12  is closed or kept closed, a higher control pressure is necessary than when the valve  12  is opened.  
         [0038]     The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations within the scope of the appended claims and equivalents thereof.