Patent Publication Number: US-2022235869-A1

Title: System and Method for High Flow Valve

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application Ser. No. 62/530,924 entitled “SYSTEM AND METHOD FOR HIGH FLOW VALVE” by Ward et al., filed Jul. 11, 2017, the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates to systems and methods for a high flow valve. 
     BACKGROUND 
     Many cartridge valves use a solenoid magnetic force to initiate a shift in valve position. Currently, high flow cartridge valves typically require a large solenoid magnetic force to initiate a shift in valve position. Such large solenoid magnetic forces use extensive power and can result in large and heavy valve assemblies. Further, an adjustable pole piece is often used to set an air gap in cartridge valves so that the initial solenoid magnetic force can initiate a shift in valve position. 
     Therefore, a significant obstacle with high flow valves is the use of extensive power and large, heavy, expensive valve assemblies. Accordingly, it will be appreciated that a high flow valve that uses less power and is smaller, lighter and less expensive is desired. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Features and advantages of the various embodiments, and the manner of attaining them, will become more apparent and will be better understood by reference to the accompanying drawings. 
         FIG. 1  is a side elevation view of a high flow valve according to an embodiment of a high flow valve in accordance with the present disclosure; 
         FIG. 2  is a cross-section view of the high flow valve illustrated in  FIG. 1  with the valve in a de-energized state; 
         FIG. 3  is a cross-section view of the high flow valve illustrated in  FIG. 1  with the valve in an energized state; 
         FIG. 4  is an end view of the high flow valve of  FIG. 1  showing the return spring; 
         FIG. 5  is a cross-section fragmentary view of the valve seal of the high flow valve of  FIG. 1   
         FIG. 6  is a cross-section fragmentary view of the diaphragm of the high flow valve of  FIG. 1 ; 
         FIG. 7  is a cross-section fragmentary view of the diaphragm illustrated in  FIG. 5  showing a portion of the valve of  FIG. 1 ; 
         FIG. 8  is a cross-sectional view of a high flow 3/2 normally closed valve; 
         FIG. 9  is cross-sectional view of a high flow 2/2 normally open valve; and 
         FIG. 10  is cross-sectional view of a high flow 2/2 normally closed valve. 
     
    
    
     DETAILED DESCRIPTION 
     For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the disclosure as would normally occur to a person of ordinary skill in the art to which this disclosure pertains. 
     Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings. 
     Turning now to the drawings, and more particularly to  FIG. 1 , an example embodiment of a high flow valve  10  in accordance with the present disclosure is illustrated. Returning to  FIG. 1 , the high flow valve  10  includes a body  12  and a valve seal  14 . The high flow valve  10  also includes a seal rod  15  on which the valve seal  14  is fixedly positioned, a return spring  16  connected to the seal rod  15  and an O-ring  18  connected to the body  12 . 
     The valve in this embodiment is a high flow 3/2 cartridge valve having three ports and a two position spool that directs air, gas, or liquid in and out of the three ports. Referring to  FIG. 1 , the three ports includes an inlet supply port “P”  32  where pressurized air or other gas enters the valve, a delivery port “A”  34  where the air is directed to the working part of the system (e.g. 02 concentrator sieve bed), and an exhaust port “R”  36  where the air from the working part of the system is exhausted to atmosphere. 
     As depicted in  FIG. 2 , the high flow valve  10  includes an armature  27  connected to the seal rodd  15 . The high flow valve  10  may further include a solenoid coil  26  and bobbin that may be energized and generate an electromagnetic field to move the armature  27 . In some embodiments, the high flow valve  10  may further include a connector cap  19 . The connector cap  19  may cover a connection to an electrical power source to provide AC or DC power to energize the solenoid coil  26  and bobbin. The high flow valve  10  may also include an armature guide tube  28  to assist with guiding the armature  27  and a pole piece  29  to attract the armature  27 . 
     As discussed below, the valve seal  14  is configured to be moved by the seal rod  15  between an exhaust seal seat  21  (e.g., when the solenoid is de-energized) and a supply seal seat  22  (e.g., when the solenoid is energized). The valve seal  14  is formed of a suitable sealing material, such as rubber, so that when the valve seal  14  is seated against the exhaust seal seat  21 , as depicted in  FIG. 2 , the delivery port A  34  is open and the exhaust port R  36  is sealed closed. When the valve seal  14  is seated against the supply seal seat  22 , as depicted in  FIG. 3 , the delivery port A  34  is sealed closed and the exhaust port R  36  is open 
     In addition, the high flow valve  10  includes a diaphragm  23 . As shown in  FIGS. 6 and 7  the diaphragm  23  may include an inner band  37  that is attached to the outer circumference of the seal rod  15  and an outer band  38  which is attached to the inner circumferential wall of the body  12 . The diaphragm  23  includes an arched portion  39  between the inner band  37  and outer band  38 . The arched potion  38  allows the diaphragm  23  to balance forces acting on the port  32  without generating a biasing force on the seal rod  15 . The inner band  37  and the outer band  38  may be attached to the seal rod  15  and body  12 , respectively, in any suitable manner. In the embodiment of  FIGS. 5 and 6 , the inner band  37  and outer band  38  include beads which enable the bands  37 ,  38  to be retained in grooves in the seal rod and body  12 , respectively. 
     In certain embodiments, tension in the inner and outer bands of the diaphragm  23  may apply radial force onto the seal rod  15  and the body  12  to compress the inner and outer beads and contain pressurized fluid. Such tension removes the need for additional parts to compress the diaphragm  23  to contain pressurized fluid and reduces the costs of the high flow valve  10 . Returning to  FIG. 2 , the high flow valve may also include an inner field plate  24  to clamp the diaphragm  23  to the body  12 . 
     The body  12 , seal rod  15 , exhaust cap  20  and inner field plate  24  of the high flow valve  10  may be made from any of a variety of materials, such as polymers, ferritic stainless steel and brass, for example. The return spring  16  may be made from any of a variety of materials, such as stainless steel, for example. The valve seal  14 , O-ring  18  and diaphragm  23  may be made from any of a variety of materials, such as rubber, for example. The connector cap  19  and solenoid bobbin may be made from any of a variety of materials, such as polymers, for example. The solenoid coil  26  may be made from any of a variety of materials, such as copper, for example. The armature  27  and pole piece  29  may be made from any of a variety of materials, such as steel, for example. The armature guide tube  28  may be made from any of a variety of materials, such as stainless steel or brass for example. 
     Turning to  FIGS. 1-4 , in multiple embodiments, the high flow valve  10  is assembled in a series of steps. First, the diaphragm  23  is pressed onto the seal rod  15 . Next, the armature  27  is pressed onto the seal rod  15 . The seal rod  15 , diaphragm  23  and armature  27  are then placed through the solenoid end of the body  12 . The diaphragm  23  is then pressed into the body  12 . Next, the inner field plate  24  is pressed into the body  12 . The solenoid coil  26  and bobbin are then placed in the body  12 . The armature guide tube  28  is then placed in the body  12  around the armature  27 . The pole piece  29  is then placed in the body  12 . Next, the valve seal  14  is pressed onto the seal rod  15 . The exhaust cap  20  is then pressed into the body  12 , the return spring  16  is placed onto the seal rod  15 , the connector cap  19  is pressed into the body  12 , and the O-ring  18  is placed onto the valve body  12 . 
       FIG. 4  depicts the return spring  16  in greater detail. As can be seen in  FIG. 4 , the return spring  16  comprises a coil spring with a short conical shape. The inner most winding of the spring is attached to the end of the seal rod  15 . To attach the inner spring end to the seal rod  15 , the inner spring end includes a bent spring arm  48  which is received in a spring groove  49  provided in the seal rod  15 . The spring arm  48  can be pried open and snapped onto the spring groove  47  which enables the spring load to be coupled to the seal rod  15  without the need for additional parts, such as a snap ring. 
     The valve seal  14  may be pressed onto the seal rod  15  while the armature  27  is positioned against the pole piece  29 . In some embodiments, the valve seal  14  may be over-pressed against the supply seal seat  22  while the armature  27  is positioned against the pole piece  29 . In certain embodiments, the valve seal  14  may be over-pressed against the supply seal seat  22  with a predetermined force or press distance, such as 0.005 in., for example. Over-pressing the valve seal  14  against the supply seal seat  22  assists in sealing the valve seal  14  at the supply seal seat  22  when the valve seal  14  moves to the supply seal seat  22 . 
       FIG. 5  depicts an embodiment of the valve seal  14  in greater detail. As can be seen in  FIG. 5 , the valve seal  14  includes a seal body  61  and a carrier or spool  62 . The seal body  61  is formed of a flexible material, such as rubber. The seal body  61  is carried on a spool  62 , which is mounted (e.g., pressed) onto seal rod  15 . The spool is formed of a sturdy, rigid material, such as brass. The spool includes a spool hub on which the seal body rests and sidewalls which extend outwardly from the hub. As can be seen in  FIG. 5 , the sidewalls of the spool extend to only a part of the way with respect to the sides of the seal body  61  which leaves the outer portion of the seal body  61  unsupported by the spool. The sidewalls of the spool add a degree of stiffness to the inner portion of the seal body  61  while leaving the outer portion of the seal body free to flex. The flexible nature of the outer portion of the valve seal  14  allows the valve seal  14  to deflect when it initially contacts a valve seat. This deflection allows for additional movement of the armature/shaft assembly once the valve seal has contacted the supply seal seat. The flexible nature of the valve seal along with the over pressing of the valve seal causes the armature to decelerate prior to contacting the pole piece. This deceleration significantly reduces the mechanical shifting noise, which is objectionable. 
     During operation, the electrical power source provides AC or DC power to the solenoid coil  26  and bobbin. The solenoid coil  26  and bobbin receive power and induce a magnetic field in the pole piece  29  and armature  27 . The pole piece  29  then attracts the armature  27  to move the valve seal  14  between the exhaust cap seal seat  21  and the supply seal seat  22 . 
     As shown in  FIG. 2 , when the solenoid coil  26  is de-energized or “off”, the return spring  16  pulls the seal rod  15  to hold the valve seal  14  against the exhaust seal seat  21 , blocking fluid from exiting the exhaust port  36  and allowing fluid to flow from the supply port  32  to the delivery port  34 . As shown in  FIG. 3 , when the solenoid coil  26  is energized or “on”, the solenoid coil  26  magnetically pulls the armature  27  and compresses the return spring  16  to hold the valve seal  14  against the supply seal seat  22 , blocking fluid from the supply port  32  and allowing fluid to flow from the delivery port  34  to the exhaust port  36 . 
     In a normally open valve configuration, when the valve seal  14  is positioned on the exhaust seal seat  21 , the valve seal  14  exerts an exhaust seal pressure force over an exhaust seal pressure area. The diaphragm  23  exerts a diaphragm force over a diaphragm pressure area and opposite the exhaust seal pressure force. In certain embodiments, the exhaust seal seat  21  has a diameter that makes the exhaust seal pressure area about equal to the diaphragm pressure area and allows the exhaust seal pressure force and the diaphragm force to balance. Such a balancing of the exhaust seal pressure force and the diaphragm force reduces the forces acting on the armature  27  and facilitates the initial movement of the armature  27  toward the pole piece  29  when the solenoid coil  26  is energized. Thus, a smaller, lower power solenoid coil  26  can be used to initiate movement of the armature  27 . Also, with the reduction of the forces acting on the armature  27  and reduction in the magnetic force needed to initiate movement of the armature  27 , the gap between the armature  27  and the pole piece  29  can be increased to provide greater valve stroke. Greater valve stroke allows a larger flow rate of fluid through the valve. 
     In other embodiments, in a normally closed valve configuration, when the solenoid coil is de-energized or “off, the return spring holds the valve seal against the supply seal seat, blocking fluid from the supply port and allowing fluid to flow from the delivery port to the exhaust port. In such embodiments, when the solenoid coil is energized or “on”, the solenoid coil magnetically pulls the armature and compresses the return spring, blocking fluid from exiting the exhaust port and allowing fluid to flow from the supply port to the delivery port. 
     The armature and pole piece air gap must be set so the initial solenoid attraction force on the armature is sufficient to initiate a shift of the valve. If the initial air gap is too great, then the valve may not shift. If the air gap is too small, then the rubber seal mat not contact the supply seat when the valve shifts. The set the armature-to-pole piece air gap, the end of the seal rod  15  is pressed toward the solenoid until the armature  27  contacts the pole piece  29 . The valve seal  14  on the seal rod is then pressed against the supply seat  22  with a calibrated amount of force to deflect the rubber seal (e.g., over-pressing). After the pressure is removed, the valve seal  14  relaxes which pulls the armature  27  away from the pole piece  29  to from a small air gap between the pole piece  29  and the armature  27 . 
     By over-pressing the rubber valve seal  14  against the supply seat  22  using a predetermined force or press distance, the rubber seal is guaranteed to properly seal at the supply seat  22  when the valve shifts and also form a small air gap at the end of valve stroke. This press technique setting the initial air gap eliminates the need of an expensive, adjustable pole piece which is often required in previously known high flow valves to set a gap so that the initial solenoid coil magnetic force can initiate a shift in valve position. 
     The solenoid coil induces a magnetic field in the ferrous pole piece, outer shell, and armature. The armature is attracted by the pole piece. The attraction force is greatly reduced when the air gap between the pole piece and armature is large. As the armature starts to move toward the pole piece, the air gap decreases and the magnet attraction force dramatically increases. Therefore, by minimizing the “other” forces acting on the armature will better permit the armature to initiate its movement when the magnetic attraction force is at its weakest. 
     One of the primary forces acting against the armature  27  is the pressure force acting on the valve seal  14  toward the exhaust seal seat  21 . To reduce the force required of the solenoid to move the armature  27  against the force exerted on the valve seal  14 , the diaphragm is configured to exert a balancing force in the opposite direction. 
     The diaphragm is of low spring rate as to transmit negligible forces to the armature in both the energized and de-energized states. The exhaust seat diameter may be adjusted to achieve optimum pressure force balance between the exhaust seal and the diaphragm by establishing equal pressure areas. Without the rubber diaphragm and its pressure force balancing, a much larger and more expensive solenoid would be needed to shift the valve. 
     The high flow valve  10  depicted and described with reference to  FIGS. 1-3  is a high flow 3/2 normally open (NO) valve.  FIGS. 8-10  depict diaphragms incorporated into other types of valves. In particular,  FIG. 8  depicts a high flow valve  10 ′ in the form of 3/2 (three port, two spool position) normally closed (NC) valves.  FIG. 9  depicts a high flow valve  10 ″ comprising a high flow 2/2 (two port, two spool position) normally open valve.  FIG. 10  depicts a high flow valve  10 ′″ comprising a high flow 2/2 (two port, two spool position) normally closed valve. The valve  10 ′ of  FIG. 7  includes three ports  41 ,  42 ,  43 . The valve  10 ″ of  FIG. 9  includes two ports  44 ,  45 , and the valve  10 ′″ of  FIG. 10  includes two ports  46 ,  47 . 
     The high flow valves of  FIGS. 8-10  each include a first diaphragm  23  which corresponds to the diaphragm  23  of the embodiment of  FIG. 13 . In addition, the high flow valves of  FIGS. 8-10  each include a second diaphragm  40  which is located on an opposite end of the seal rod  15  from the first diaphragm  23 . The use of two diaphragms arranged in this manner enables further balancing of the “other” forces acting with or against the movement of the armature and seal rod. The second diaphragm  40  has a configuration similar to the configuration of the first diaphragm. In particular, the second diaphragm may include an inner band that is attached to the outer circumference of the seal rod  15  near the outer end of the seal rod. The second diaphragm includes an outer band which is attached to the inner circumferential wall of the body  12 . The second diaphragm  40  also includes an arch-shaped portion. The second diaphragm  40  is arranged in the valve with the arch-shaped portion facing outwardly and opposite to arch-shaped portion of the first diaphragm. 
     In the embodiment of  FIG. 8 , the first diaphragm  23  is configured to generate a balancing force that is equal to and opposite from any non-solenoid forces acting on the valve seal  14  in the direction toward the exhaust seal seat  21 . The second diaphragm  40  is configured to generate a balancing force that is equal to and opposite from any non-solenoid forces acting on the valve seal in the direction toward the supply seal seat  22 . The use of the dual diaphragm construction provides balanced forces on the armature/shaft assembly with pressure or vacuum applied to any port, such as the three ports  41 ,  42 ,  43  of the high flow 3/2 NC valve of  FIG. 8 , the two ports  44 ,  45  of the high flow 2/2 NO valve of  FIG. 9 , and the two ports  46 ,  47  of the high flow 2/2 NC valve of  FIG. 10 . This in contrast to the valve  10  shown in  FIGS. 1-3  which is only balanced which pressure is applied to port  32 . 
     As described above, the configuration of the high flow valve  10  is small, lightweight and uses less power relative to previously known high flow valves. The high flow valve  10  provides an efficient and cost-effective method to provide a high flow rate of fluid. 
     While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected.