Patent Publication Number: US-2010108927-A1

Title: Silent solenoid valve for fluid regulation system

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of provisional patent application No. 61/111,777, filed Nov. 6, 2008, which is hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to fluid regulators, and more specifically to gas regulators having solenoid valves. 
     2. Description of the Related Art 
     Gas regulators, including those having one and two-solenoid valve configurations (e.g., being connected in series fluid communication), have been used in various gas-fired appliances (e.g., gas fireplaces, space heaters, ovens, furnaces, water heaters, agricultural heaters, and so forth) for several years. These gas valves are typically operated electrically, and are generally incorporated into a regulator system that controls the flow of gas into the particular appliance. 
     Typically, as shown in  FIG. 1 , these gas valves employ a plunger P housed in a solenoid sleeve S. A terminal portion of the plunger P is provided with a plunger eyelet E that is at least partially disposed in a generally circular recess R formed on the tip portion of the plunger P, with a portion of the plunger eyelet E extending out from the recess R and forming a substantially circular rounded exterior lip portion L. The plunger eyelet E is typically comprised of a metallic material, such as but not limited to brass. When the solenoid is energized (e.g., through the application of electrical energy to the solenoid), the plunger P is forced towards a plunger stop PS such that the lip portion L of the plunger eyelet E strikes the plunger stop PS, simultaneously lifting a valve member off of its valve seat, and thus allowing gas to flow through the regulator and eventually through to the appliance. The plunger stop PS is typically also comprised of metal, such as but not limited to steel. Unfortunately, the striking of these two metallic surfaces against one another typically generates a “clicking” noise that most consumers find undesirable. 
     Accordingly, there exists a need for new and improved solenoid gas valves for use with various types of gas-fired appliances that overcome at least one of the aforementioned problems. 
     SUMMARY OF THE INVENTION 
     The present invention discloses a fluid regulator system. The system includes a housing. The housing defines an inlet for receiving a fluid, a passage in fluid communication with the inlet for accommodating the fluid, and an outlet in fluid communication with the passage for discharging the fluid. The system also includes a regulator for regulating flow of the fluid through the passage. At least one solenoid valve interrupts the flow of the fluid through the passage. The at least one solenoid valve includes a valve member disposed inline with the passage and movable between an open position and a closed position. A plunger having a top, a bottom, and a side wall extends between the top and the bottom. The bottom is operatively connected to the valve member for moving the valve member between the positions. A recess is defined in the top of the plunger. A solenoid is disposed around at least a portion of the plunger for actuating the plunger. A plunger stop is disposed adjacent the top of the plunger for stopping movement of the plunger when the valve member is in the open position. A plunger bumper assembly is disposed at least partially within the recess of the top of the plunger and at least partially between the top of the plunger and the plunger stop. The plunger bumper assembly includes a resilient component formed of a resilient material for dampening noise produced by a contact between the plunger bumper assembly and the plunger stop. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
         FIG. 1  is a partial cross-sectional view of a prior art solenoid valve plunger; 
         FIG. 2  is a partial cross-sectional view a fluid regulating system of the subject invention with valve members in a closed position; 
         FIG. 3  is a partial cross-sectional view the fluid regulating system of the subject invention with the valve members in an open position; 
         FIG. 4  is a partial cross-sectional view of a first embodiment of a plunger of a solenoid valve detailing a plunger bumper assembly; 
         FIG. 5  is a perspective view of the first embodiment of the plunger; 
         FIG. 6  is a partial cross-sectional view of a second embodiment of the plunger of the solenoid valve detailing the plunger bumper assembly; and 
         FIG. 7  is a perspective view of the second embodiment of the plunger. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a fluid regulator system  1  is shown herein. In the illustrated embodiments, the fluid is a gas, such as a combustible gas. However, those skilled in the art realize the other gases or fluids may be implemented within the scope of the described invention. 
     With reference to  FIGS. 2 and 3 , the system  1  includes a body housing  30 . The housing  30  defines an inlet  10  for receiving a fluid and an outlet  200  for discharging the fluid. An inlet screen  20  is disposed within the inlet  10  for filtering the fluid. The housing  30  also defines a passage  32  fluidically connecting the inlet  10  to the outlet  200 . The housing  30  may be formed of a cast metal; however, those skilled in the art realize other techniques and materials used to form the housing  30 . 
     The system  1  includes an inlet valve  34  and an outlet valve  36  each disposed to interrupt flow of the fluid through the passage  32 . Specifically, the inlet valve  34  interrupts flow of the fluid adjacent the inlet  10  while the outlet valve  36  interrupts flow of the fluid adjacent the outlet  200 . However, those skilled in the art realize that a single valve could be implemented instead of the pair of valves  34 ,  36 . 
     The system  1  also includes a regulator  38  to regulate flow of the fluid through the passage  32 . Specifically, the regulator  38  is fluidically disposed between the inlet and outlet valves  34 ,  36 . The regulator  38  includes a regulator valve seat  210  cooperating with a regulator valve member  220 . An adjusting screw  230  operates to move the regulator valve member  220 , and thus regulate the flow of the fluid. A spring  240  is connected to both the adjusting screw  230  and the regulator valve member  220 . A seal cap  232  protects the adjusting screw  230 . The regulator  38  also includes a diaphragm  250 , a dust cap  260 , and a vent limiting orifice  270 . 
     The inlet valve  34  includes an inlet valve member  160  and the outlet valve  36  includes an outlet valve member  160   a . Each valve member  160 ,  160   a  is disposed inline with the passage  32 . The valve members  160 ,  160   a  are movable between an open position, in which fluid may flow through the passage  32  adjacent the member  160 ,  160   a , and a closed position, in which fluid is blocked from flowing through the passage  32  adjacent the  160 ,  160   a . In the illustrated embodiments, the valve members  160 ,  160   a  are each disc shaped and include a valve insert  150 . Also in the illustrated embodiments, the housing  30  defines an inlet valve seat  190  and an outlet valve seat  190   a  for interfacing with the respective valve members  160 ,  160   a . However, those skilled in the art appreciate other techniques for opening and closing the passage  32 , besides the disc-shaped valve members  160 ,  160   a  and seats  190 ,  190   a  shown herein. 
     The valves  34 ,  36  of the illustrated embodiment are solenoid valves. That is, each valve  34 ,  36  utilizes a solenoid  70 ,  70   a , also commonly referred to as a coil, to actuate the valve members  160 ,  160   a  between open and closed positions. The valves  34 ,  36  each include an electrical connector  60 ,  60   a  electrically connected to the solenoids  70 ,  70   a  for supplying electric current to the solenoids  70 ,  70   a . The solenoids  70 ,  70   a  of the illustrated embodiment are supported by a frame  50 . A gasket  40  is sandwiched between the frame  50  and the housing  30 . 
     Each valve  34 ,  36  includes a plunger  120 ,  120   a  disposed within the solenoid  70 ,  70   a  and operatively connected to the valve member  160 ,  160   a . The plunger  120 ,  120   a  is preferably formed of a magnetic member, such that movement of the plunger  120 ,  120   a  occurs when the solenoid  70 ,  70   a  is energized, i.e., when electric current is applied to the solenoid  70 ,  70   a.    
       FIG. 2  shows the fluid regulator system  1  with the valves  34 ,  36  in the closed position, in that fluid is not able to flow through the system  1 . More specifically, the inlet valve member  160  is pressed relatively tightly against the inlet valve seat  190 , and the outlet valve member  160   a  is pressed relatively tightly against the outlet valve seat  190   a . The force to keep the inlet solenoid valve  160  and the outlet solenoid valve  160   a  pressed relatively tightly against the inlet valve seat  190  and the outlet valve seat  190   a , respectively, is supplied by an inlet plunger spring  130  and an outlet plunger spring  130   a , respectively. Thus, by way of a non-limiting example, when the respective solenoids  70  and  70   a  are not energized, the inlet plunger spring  130  and outlet plunger spring  130   a  provide a sufficient spring force to keep the fluid regulator system  1  from allowing any gas flow therethrough. It should also be noted that only one of either the inlet valve member  160  or the outlet valve member  160   a  needs to be in contact against their respective valve seat, i.e., inlet valve seat  190  or outlet valve seat  190   a , in order to prevent fluid flow through the entirety of the fluid regulator system  1 . 
     Referring now to  FIG. 3 , when it is desired to allow the fluid to flow through the system  1 , it is necessary to cause at least one, and preferably both of the inlet valve member  160  and the outlet valve member  160   a  to be lifted off of their respective valve seats, i.e., the inlet valve seat  190  and the outlet valve seat  190   a . Typically, this is accomplished by energizing (e.g., by the application of an electric current) one or both of the respective solenoids  70 ,  70   a , which are coupled, either directly or indirectly, to their respective valves members, i.e., the inlet valve member  160  and the outlet valve member  160   a . It should be noted that the respective solenoids  70 ,  70   a  can be energized simultaneously or in sequence (e.g., the inlet solenoid  70   a  can be energized first and then the outlet solenoid  70   a  can be energized thereafter, or if desired for whatever reason, the outlet solenoid  70   a  can be energized first and then the inlet solenoid  70  can be energized thereafter). 
     When the respective solenoids  70 ,  70   a  are energized, the respective inlet plunger  120  and outlet plunger  120   a  are forced (in this case, upwardly, overcoming the spring force of inlet plunger spring  130  and outlet plunger spring  130   a , respectively) towards their respective plunger stop  100 ,  100   a . Specifically, the inlet valve  34  includes an inlet plunger stop  100  and the outlet valve  36  includes an outlet plunger stop  100   a . In this manner, fluid flow through the system can be achieved. The fluid flow is shown by the series of arrows. 
       FIGS. 4 and 5  show a first embodiment of the plungers  120 ,  120   a  while  FIGS. 6 and 7  show a second embodiment of the plungers  120 ,  120   a . Each plunger  120 ,  120   a  includes a top  312 , a bottom  313 , and a side wall  314  extending between the top  312  and the bottom  313 . In these illustrated embodiments, the side wall  314  has a cylindrical shape. The top  312  and bottom  313  each have a frustoconical shape, as can be seen in  FIGS. 7 and 9 . That is, the top  312  and bottom  313  each have an angled portion (not numbered) extending inward away from the side wall  314  and a flat portion  316 , wherein a diameter of the flat portion  316  is less than a diameter across the side wall  314 . 
     The bottom  313  of each plunger  120 ,  120   a  is connected to the respective valve member  160 ,  160   a , as can be seen in  FIGS. 2 and 3 . The plunger springs  130 ,  130   a  are also preferably connected to the bottom  313  of each respective plunger  120 ,  120   a.    
     A recess  310  is defined by the top  312  of each plunger  120 ,  120   a . More specifically, the recess  310  is a cylindrical hole extending downward from the flat portion  316  of the top  312 . Each valve  32 ,  34  also includes a plunger bumper assembly  110 ,  110   a . Each assembly  300  is disposed at least partially within the recess  310 . Specifically, each assembly  300  is connected to the plunger  120 ,  120   a  within the recess  310 . 
     Each assembly  300  includes a resilient component (not separately numbered) for dampening noise produced by the contact caused by the energization of the solenoid  70 ,  70   a . Specifically, the resilient component dampens noise caused by the contact between each plunger  120 ,  120   a  and each plunger stop  100 ,  100   a , when the valve member  160 ,  160   a  is moved to the open position. 
     In the first embodiment, as shown in  FIGS. 4 and 5 , the plunger bumper assembly  300  includes a plunger recess part  302 . The plunger recess part  302  includes a base portion  308  and a lip portion  306 . The base portion  308  is disposed at least partially within the recess  310 . As such, the base portion  308  has a cylindrical shape to cooperate with the cylindrical shape of the recess  310 . The lip portion  306  extends generally perpendicularly away from the base portion  308  to define a ring shape. The lip portion  306  is separated from, i.e., does not make direct contact with, the top  312  of the plunger  120 ,  120   a . The plunger recess part  302  is preferably formed of a metal, however, other materials, such as plastics, may be used, as is known to those skilled in the art. Regardless of the particular material chosen, the plunger recess part  302  should be durable, rigid, and if possible, non-magnetic. Said another way, the plunger recess part  302  may be non-resilient. 
     The resilient component of the plunger bumper assembly  300  of the first embodiment is an o-ring  304 . The o-ring  304  is disposed between the lip portion  306  and the top  312  of the plunger  120 ,  120   a . The o-ring  304  is preferably formed of a resilient material such as rubber. However, foams, relatively soft and flexible plastics, and/or the like, and other materials may also be utilized for the o-ring  304 . Regardless of the particular material chosen, the o-ring  304  should be durable, resilient, and if possible, non-magnetic. Thus, in this first embodiment, when the lip portion  306  of strikes the plunger stop  318 , the o-ring  304  cushions the impact of the two surfaces, thus reducing the resulting sound of the impact. 
     In the second embodiment, as shown in  FIGS. 6 and 7 , the resilient component of the plunger bumper assembly  110 ,  110   a  includes a base portion  404  and a head portion  412 . The base portion  404  is disposed within the recess  310  of the plunger. The resilient component of the plunger bumper assembly  300  of the second embodiment is at least the head portion  412 . That is, the head portion  412  is formed of rubber, foam, plastic, or other durable, resilient materials. The head portion  412  has generally circular shaped or mushroom shaped. The base portion  404  may also be considered part of the resilient component. That is, the base portion  404  may also be formed of rubber, foam, plastic, etc. Specifically, the base portion  404  and the head portion  412  are integrally formed of a common material. That is, the base portion  404  and the head portion  412  have one-piece construction. However, those skilled in the art realize that the base portion  404  and head portion  412  may formed of different materials and simply attached together by known means. 
     The present invention has been described herein in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the invention are possible in light of the above teachings. The invention may be practiced otherwise than as specifically described within the scope of the appended claims.