Patent Publication Number: US-2018031131-A1

Title: Self-aligning valve seal

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional application of U.S. Ser. No. 14/934,285, filed on Nov. 6, 2015, which claims priority to and all benefit of U.S. Provisional Patent Application Ser. No. 62/076,710, filed on Nov. 7, 2014, for SELF-ALIGNING VALVE SEAL, the entire disclosures of which are fully incorporated herein by reference. 
    
    
     TECHNICAL FIELD OF THE INVENTIONS 
     The inventions relate to fluid flow and delivery devices and methods, and more particularly to poppet valves used to control fluid flow and delivery. 
     BACKGROUND OF THE INVENTIONS 
     Poppet style valves are well known for use as flow control mechanisms for gas and liquid fluid delivery, flow control, and pressure control. Poppet valve arrangements include an axially movable stem having an enlarged disc or head portion that seals against an annular seat in a valve passage when the stem is in a closed position and axially separates from the seat when the stem is in an open position, to permit fluid flow through the valve passage. Many different types of fluid control devices utilize poppet valve mechanisms, including, for example, diaphragm valves, bellows valves, and pressure regulators. 
     SUMMARY OF THE INVENTIONS 
     A first inventive concept presented herein provides a poppet type valve arrangement having a laterally movable sealing member for self-alignment of a poppet sealing surface with a seating surface of a valve seat as the poppet is axially moved with respect to the valve seat from an open position to a closed position. In one such embodiment, the laterally movable sealing member is a poppet sealing member assembled with an axially moveable poppet, for self-aligning sealing engagement of the poppet sealing member with an annular valve seat. 
     Accordingly, in an exemplary embodiment, a valve includes a valve body, a valve seat, and a poppet assembled with the valve body. The poppet includes an axially extending poppet stem and a radially extending poppet sealing surface. The poppet is axially movable between a closed position and an open position. The poppet sealing surface is defined by a sealing member disposed on the poppet stem. The sealing member is laterally movable on the poppet stem. When the poppet is moved from the open position to the closed position, the sealing member is laterally moved to align the sealing surface with the seating surface. 
     In another exemplary embodiment, a valve includes a valve body, a valve seat surrounding an axially extending portion of a flow path through the valve body, and a poppet assembled with the valve body. The poppet includes upper and lower portions laterally fixed in the valve body, and a radially extending poppet sealing surface disposed on a central portion of the poppet between the laterally fixed upper and lower portions. The poppet is axially movable between a closed position in which the poppet sealing surface seals against a seating surface of the valve seat, and an open position in which the poppet sealing surface axially separates from the seating surface of the valve seat. The poppet sealing surface is defined by a sealing member disposed on the poppet stem. At least one of the poppet sealing member and the valve seat is laterally movable with respect to the other of the poppet sealing member and the valve seat, such that when the poppet is moved from the open position to the closed position, the poppet sealing member and/or the valve seat is laterally moved to align the poppet sealing surface with the valve seating surface. 
     In another exemplary embodiment, a pressure regulator includes a body, a valve seat surrounding an axially extending portion of a flow path of the body, a poppet assembled with the valve body, a poppet driving mechanism assembled with the poppet stem, and a biasing mechanism. The poppet includes an axially extending poppet stem and a radially extending poppet sealing surface. The poppet is axially movable between a closed position in which the poppet sealing surface seals against a seating surface of the valve seat and an open position in which the poppet sealing surface axially separates from the valve seat. The biasing mechanism applies a biasing force to an upper surface of the poppet driving mechanism to bias the poppet toward one of the open and closed positions. The poppet driving mechanism is configured to be biased toward the other of the open and closed positions by fluid pressure applied to a lower surface of the poppet driving mechanism. The poppet sealing surface is defined by a sealing member disposed on the poppet stem. The sealing member is laterally movable on the poppet stem, wherein when the poppet is moved from the open position to the closed position, the sealing member is laterally moved to align the sealing surface with the seating surface. 
     In another exemplary embodiment, a poppet subassembly for a valve includes a poppet stem extending in an axial direction and including a neck portion extending axially between enlarged upper and lower portions of the poppet, and an annular poppet sealing member disposed around the neck portion and captured between the enlarged upper and lower portions of the poppet. The annular poppet sealing member has an inner diameter sized to permit lateral movement of the poppet sealing member with respect to the neck portion between a centered position defining a concentric radial gap between the poppet stem neck portion and the poppet sealing member, and an off-center position defining an eccentric radial gap between the poppet stem neck portion and the poppet sealing member. 
     These and other inventive concepts are fully disclosed hereinbelow, and will be readily understood by those skilled in the art from the following detailed description of the exemplary embodiments in view of the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional schematic illustration of a poppet type valve assembly, in accordance with an exemplary embodiment of the present application; 
         FIG. 2  is an enlarged view of a poppet sealing portion of the poppet type valve assembly of  FIG. 1 , shown in an open position, with deviations in sealing surface alignment exaggerated to more clearly illustrate the self-aligning properties of the poppet sealing portion; 
         FIG. 3  is an enlarged view of the poppet sealing portion of the poppet type valve assembly of  FIG. 1 , shown in a closed position, with adjustment of the poppet sealing portion exaggerated to more clearly illustrate the self-aligning properties of the poppet sealing portion; 
         FIG. 4A  is a cross-sectional schematic illustration of a poppet sealing arrangement, in accordance with an exemplary embodiment of the present application; 
         FIG. 4B  is a cross-sectional schematic illustration of another poppet sealing arrangement, in accordance with an exemplary embodiment of the present application; 
         FIG. 5  is a cross-sectional view of a pressure regulator, in accordance with an exemplary embodiment of the present application; 
         FIG. 5A  is a perspective cross-sectional view of the pressure regulator of  FIG. 5 ; 
         FIG. 6  is an enlarged view of a poppet sealing portion of the pressure regulator of  FIG. 5 , shown in an open position, with deviations in sealing surface alignment exaggerated to more clearly illustrate the self-aligning properties of the poppet sealing portion; 
         FIG. 7  is an enlarged view of the poppet sealing portion of the pressure regulator of  FIG. 5 , shown in a closed position, with adjustment of the poppet sealing portion exaggerated to more clearly illustrate the self-aligning properties of the poppet sealing portion; 
         FIG. 8  is an enlarged view of a poppet sealing portion of another pressure regulator, in accordance with another exemplary embodiment of the present application; 
         FIG. 9  is an enlarged view of a poppet sealing portion of another poppet type valve assembly, in accordance with another exemplary embodiments of the present application, shown in an open position, with deviations in sealing surface alignment exaggerated to more clearly illustrate the self-aligning properties of the poppet sealing portion; and 
         FIG. 10  is an enlarged view of the poppet sealing portion of the poppet type valve assembly of  FIG. 9 , shown in a closed position, with adjustment of the poppet sealing portion exaggerated to more clearly illustrate the self-aligning properties of the poppet sealing portion. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     This Detailed Description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the invention as claimed is broader than and unlimited by the exemplary embodiments, and the terms used in the claims have their full ordinary meaning. For example, while the specific embodiments described herein relate to diaphragm sealed pressure-reducing regulator valve arrangements, the features of the present application may additionally or alternatively be applied to other types of valves, including, for example, back-pressure regulator valve arrangements, shutoff valves, check valves, and relief valves, and other sealing mechanisms, including, for example, bellows sealing and o-ring/gasket sealing arrangements. The terms “poppet valve” and “poppet type valve,” as used herein, are intended to broadly include any valve that includes a stem that carries a sealing member that is brought into sealing engagement with an annular seat by longitudinal movement of the stem. The terms “seal” and “sealing engagement” are intended to include conditions of reduced flow resulting from contact between a sealing surface and a seating surface, in addition to a leak-tight or fluid-tight seal. 
     With reference to  FIGS. 1-3 , in an exemplary embodiment, a poppet type valve assembly  10  includes a valve body  20  defining a valve passage  22  between inlet and outlet ports  21 ,  23 , and an annular valve seat  30  extending around an axially extending portion  24  of the valve passage. A poppet  40  is assembled with the valve body  20  and includes an axially extending poppet stem  41  and a radially extending poppet sealing portion  42 . An actuator  50  is assembled with the poppet stem  41  to control axial movement of the poppet  40  between a closed position, in which the poppet sealing portion  42  seals against the valve seat  30  (e.g., to prevent flow above an allowable leak rate), and an open position, in which the poppet sealing portion axially separates from the valve seat to permit fluid flow through the axially extending portion  24  of the valve passage  22 . The actuator  50  may be user operable (e.g., manually, pneumatically, or electrically operable) for selective movement of the poppet  40 . Alternatively, the actuator  50  may be configured to automatically move or permit movement of the poppet under certain predetermined system conditions. For example, an actuator arrangement may be configured to cause or permit automatic movement of the poppet  40  at a threshold system fluid pressure, for example, to relieve excess fluid pressure from a system (in the case of a relief valve), to prevent backflow (in the case of a check valve), or to reduce an outlet pressure (in the case of a pressure regulator). Examples of pressure regulators with poppet type valve arrangements are disclosed in a product catalog titled PRESSURE REGULATORS RHPS SERIES, which is publicly available online and otherwise from Swagelok Company, and is fully incorporated herein by reference. 
     In some valve assemblies, dimensional deviations of any one or more of the valve housing, valve seat, actuator, poppet stem, and poppet sealing portion, as well as any one or more other valve components, may result in misalignment of the poppet sealing portion and the valve seat. This misalignment may cause system fluid leakage past the poppet sealing portion and the valve seat when the poppet is in the closed position. Use of seats and sealing portions of harder materials (e.g., materials having a hardness of at least 90 SHORE D), for example, metals and harder plastics, such as polyetheretherketone (PEEK), for example, in high pressure and/or high temperature applications, may result in greater susceptibility to seat leakage from even minor seat-seal misalignment. Use of narrow or line engagement between the valve seat and poppet sealing portion may also cause greater susceptibility to seat leakage from seat-seal misalignment. Minor leakage, particularly at high pressures, can cause erosion of the sealing surfaces, leading to more significant leakage past the valve seat. Further, in some poppet type valve assemblies, the axially movable poppet is laterally fixed both above and below the sealing portion, which presents additional locations for tolerance stack-up deviations or other such misalignments to cause inadequate sealing engagement between the valve seat and the poppet sealing portion. Additionally, in some valve assemblies, a closing force applied to the poppet stem may be minimal, such that forced deflection or deformation of the seat and sealing portions is insufficient to compensate for sealing surface misalignment. 
     In accordance with an aspect of the present application, to improve alignment of the valve seat and the poppet sealing portion of a poppet type valve assembly, at least one of the valve seat and the poppet sealing portion may be laterally movable with respect to the other of the valve seat and the poppet sealing portion, for aligning adjustment of the relative lateral positions of the valve seat and the poppet sealing portion. In such an arrangement, contoured surfaces (e.g., chamfered, frustoconical, or other angled seating surfaces) of one or both of the valve seat and the poppet sealing portion may facilitate self-alignment of the valve seat and the poppet sealing portion as the poppet is moved to the closed position, by directing the axial closing force on the poppet in a lateral direction. 
     In the valve assembly  10  of  FIGS. 1-3 , the poppet sealing portion  42  is laterally movable on the poppet  40 , such that when the poppet is moved from the open position ( FIG. 2 ), in which a radial seat-seal misalignment may exist, to a closed position ( FIG. 3 ), the axial closing force between the valve seat  30  and the poppet  40  is directed against the poppet sealing portion  42  to laterally move the poppet sealing portion for automatic alignment of the poppet sealing portion with the valve seat  30 . 
     Many different types of laterally movable poppet sealing portions may be utilized, including, for example, a seal disc  42   a  loosely captured radially by a cuff or collar portion  43   a  on the poppet stem  41   a  (see  FIG. 4A ), or an annular sealing ring  42   b  disposed around a neck portion  43   b  of the poppet stem  41   b  (see  FIG. 4B ). 
     Laterally movable seat and/or poppet sealing portions, as described herein, may be utilized in a variety of poppet type valve assemblies, including shutoff valves, switching valves, relief valves, check valves, and regulator valve assemblies. In an exemplary embodiment, a pressure regulator includes a laterally movable poppet sealing portion configured to align with a valve seat when the poppet is moved to the closed position. 
       FIGS. 5-7  illustrate an exemplary pressure regulator  100  including a body  120  defining a passage  122  between inlet and outlet ports  121 ,  123 , and an annular valve seat  130  extending around an axially extending portion  124  of the passage. In the illustrated embodiment, the valve seat  130  is assembled with the body  120 , for example, to permit replacement of a worn or damaged valve seat. The valve seat  130  is removable from the body  120  by removal of a plug portion  128  assembled (e.g., threadably assembled) with the body. An o-ring  131  provides a fluid tight seal between the valve seat  130  and the body  120 . 
     A poppet  140  is installed in the body  120  and includes an axially extending poppet stem  141  and a radially extending poppet sealing member  142 . As shown, the poppet sealing member may be rotationally symmetrical (i.e., having a continuous circumferential profile), on the inner diameter, on the radially outer surface, or both. In other embodiments (not shown), the poppet sealing member may have a discontinuous circumferential profile (e.g., segmented flanges, fingers, etc.), for example, to facilitate assembly of the poppet sealing member on the poppet. A plate member  151  is assembled with the poppet stem  141  to control axial movement of the poppet  140  between a closed position, in which the poppet sealing member  142  seals against the valve seat  130 , and an open position, in which the poppet sealing member axially separates from the valve seat to permit fluid flow through the axially extending portion  124  of the valve passage  122 . 
     To withstand high system pressures (e.g., up to 6000 psi) without significant material flow or erosion, the valve seat and poppet sealing member may be provided in sufficiently hard, wear resistant materials (for example, metal or plastic materials having a hardness of at least 90 SHORE D). For example, the valve seat may be provided in stainless steel and the poppet sealing member may be provided in polyetheretherketone (PEEK). 
     The regulator  100  is configured to apply a downward opening force to the poppet  140  to maintain the poppet in the open position as long as the outlet system pressure (either within the regulator or downstream of the regulator, as described in greater detail below) does not exceed a predetermined threshold. An actuator (not shown) is assembled with the body  120  and is configured to apply a downward biasing force against a diaphragm  153  assembled with the body  120  above the plate member  151 . The downward biasing force may be user adjustable to be set to a force that is equal to or slightly above an upward force applied to the diaphragm  153  by a desired maximum outlet pressure of the regulator  100 . When the outlet system pressure is below the predetermined threshold, the downward force of the actuator on the diaphragm  153  causes the diaphragm to flex downward, against the outlet system pressure, to push or move the plate member  151  and poppet  140  downward to an open position. When the outlet pressure forces against the diaphragm  153  are greater than or equal to the downward biasing force applied by the actuator, the outlet pressure acts on the diaphragm to overcome the downward biasing force, pulling or moving the plate member  151  upward for pulling movement of the poppet  140  to the closed position. Where the forces applied to the diaphragm  153  by the outlet system pressure are only slightly greater than the downward biasing force applied by the actuator, the resulting closing forces applied to the poppet  140  are minimal (e.g., a closing force approaching zero), and precise alignment of the valve seat  130  and the poppet sealing member  142  may be required to effect a leak tight seal. 
     Many different types of actuators may be utilized to apply a selected downward biasing force against the diaphragm. For example, a pressurized dome chamber may be assembled above the diaphragm  153  to apply a downward biasing force set by pressurizing the dome chamber (e.g., with pressurized air) to a user selected pressure corresponding to a required downward biasing force. In another exemplary embodiment, an actuator arrangement may include a compressed spring that applies a downward biasing force (directly or indirectly) to the diaphragm. In one such embodiment, compression of the spring may be adjustable to increase or decrease the downward biasing force exerted by the spring. For example, a spring guide engaging the upper end of the spring may be lowered or raised (e.g., by a rotatable knob or handle) to increase or reduce the compression of the spring. Exemplary dome pressurized and spring loaded actuating arrangements are described in the above incorporated PRESSURE REGULATORS RHPS SERIES catalog. Other types of poppet driving mechanisms may also be used instead of the diaphragm, such as, for example, a gasket sealed piston, as described in the above incorporated PRESSURE REGULATORS RHPS SERIES catalog. 
     The exemplary poppet  140  includes a poppet stem  141  that extends through a fixed body plate  125  in the regulator body  120  for engagement with the plate member  151 , such that the upper portion of the poppet stem  141  is laterally fixed by the body plate  125  (e.g., at o-ring seal  127 ). Holes  125 ′ may be provided in the body plate  125  to allow the outlet system pressure to pressurize the diaphragm plate  151  and the diaphragm  153 . Alternatively, a port  125 ″ may be provided through the body  120  above the body plate  125  for connection with external downstream system pressure, such that the diaphragm  153  is isolated from the outlet pressure in the regulator and senses the external downstream system pressure. 
     The lower end of the poppet stem  141  is threadably assembled with a poppet base  145  that extends into a plug portion  128  of the regulator body  120 , such that the poppet base  145  is laterally fixed by the plug portion  128  (e.g., at o-ring seal  146 ). The annular poppet sealing member  142  is captured around a neck portion  143  of the poppet stem, between a radially extending or enlarged upper rim portion  147  of the poppet stem  141  and an upper end face  148  of the enlarged lower poppet base portion  145 . The poppet sealing member  142  is positioned such that a contoured (e.g., chamfered, radiused, frustoconical, or otherwise angled) outer sealing surface  149  sealingly engages a corresponding sealing or seating surface  139  of the seat  130  (which may also be suitably contoured) when the poppet  140  is in the closed position. The poppet stem  141  includes internal ports  141 ′ which, coupled with the o-ring seal  146 , balance the poppet  140  and reduces the area of the poppet on which the inlet pressure acts. A spring  165  compressed between the poppet  140  and the body plug portion  128  applies a closing force to the poppet in the absence of pressurized fluid in the regulator  100 . 
     To allow the poppet sealing member  142  to laterally move on the poppet stem  141  for adjustable alignment with the seat  130  when the poppet  140  is moved to the closed position, the annular poppet sealing member is provided with an inner diameter D i  that exceeds an outer diameter D o  of the poppet stem neck portion  143  by a differential amount sufficient to permit adequate seat-aligning lateral movement of the poppet sealing member  142  (see  FIG. 6 ). As shown, the resulting radial gap between the poppet stem neck portion  143  and the rotationally symmetrical inner diameter of the poppet sealing member extends along an entire axial length of the poppet sealing member, to allow for uniform lateral movement without radial compression or deformation of the poppet sealing member. As a result, when the poppet  140  is moved to the closed position ( FIG. 7 ), axial engagement of the suitably contoured sealing surfaces  139 ,  149  can laterally move the poppet sealing member  142  to an off-center position (i.e., defining an eccentric radial gap between the poppet stem neck portion  143  and the poppet sealing member  142 ) up to one half of this differential amount from a centered position of the poppet sealing member (i.e., defining a concentric radial gap between the poppet stem neck portion  143  and the poppet sealing member  142 ), for aligned sealing engagement between the poppet sealing member and the seat  130 . In an exemplary embodiment, a regulator having a valve seat inner diameter of approximately 60 mm has a poppet sealing member  142  with an inner diameter D i  that exceeds an outer diameter D o  of the poppet stem neck portion  143  by a differential amount of approximately 1 mm. 
     To permit lateral movement of the captured poppet sealing member  142 , the poppet sealing member may be provided with a height dimension h p  that is slightly smaller than a neck height h n  between a lower surface  147 ′ of the rim portion  147  and the upper end face  148  of the poppet base  145 . The neck height h n  may be restricted by a shoulder portion  144  of the poppet stem  141  ( FIGS. 6 and 7 ) against which the upper end face  148  abuts upon full threaded assembly of the poppet base  145  with the poppet stem. This axial gap dimension (e.g., less than 0.5 mm, or approximately 0.3 mm) may also permit the poppet sealing member  142  to tilt on the poppet stem  141  to overcome an angular misalignment between the sealing surfaces  139 ,  149  of the valve seat  130  and the poppet sealing member  142 . To prevent inlet port leakage past the poppet sealing member  142 , a flexible annular gasket seal  161  (e.g., an o-ring) may be secured between the poppet sealing member  142  and the poppet base  145 . In the illustrated embodiment, the gasket seal  161  is retained in an annular groove  145 ′ in the upper end face  148  of the poppet base  145 , with the gasket seal  161  being compressed by and sealing against a lower surface of the poppet sealing member  142 . In an alternative embodiment, as shown in  FIG. 8 , a gasket seal  161   a  may be retained in an annular groove  142   a ′ in the lower surface of the poppet sealing member  142   a , with the gasket seal  161   a  being compressed by and sealing against the upper end face  148   a  of the poppet base  145   a.    
     According to another inventive aspect of the present application, as shown schematically in  FIGS. 9 and 10 , a poppet type valve assembly may include an annular valve seat  230  that is laterally movable within a valve body  220 , and a poppet  240  having a sealing portion  242  that is integral with or laterally fixed on the poppet. When the poppet  240  is moved from the open position ( FIG. 9 ), in which a seat-seal misalignment may exist, to a closed position ( FIG. 10 ), the axial closing force between the valve seat  230  and the sealing surface  249  of the poppet sealing member  242  is directed against the sealing surface  239  of the valve seat  230  to laterally move the valve seat for automatic alignment of the valve seat with the poppet sealing member  242 . Many different types of laterally movable valve seats may be utilized. In the illustrated embodiment, the valve seat  230  is formed as an annular sealing ring loosely captured radially by a cuff or collar portion  229  on the valve body. An o-ring  231  may provide a seal between the valve seat  230  and the valve body  220 . In another exemplary embodiment (not shown), a valve assembly may include a laterally movable valve seat and a laterally movable poppet sealing member, such that both the valve seat and the poppet sealing member may be laterally adjusted during valve closure for self alignment of the seat-seal engagement. 
     Any suitable materials may be used to provide adequate sealing performance within the valve. For example, the valve seat may be provided in stainless steel, polyetheretherketone (PEEK), or polychlorotrifluoroethene (PCTFE). The poppet sealing member may be formed from PEEK, PCTFE, ethylene propylene diene monomer (EPDM), perfluoro-elastomer (e.g., FKM or FFKM), or nitrile. The gasket/o-ring seals may be formed from EPDM, perfluoro-elastomer, or nitrile. 
     While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, hardware, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.