Patent Description:
Valves (e.g., gas or fluid) may utilize bleed conduits to bleed a portion of a flow to an internal piston assembly that drives a valve closure. Internal motors may control the extent that bleed flow reaches the piston assemblies. Such motors may have a low tolerance for exposure to debris. <CIT> describes a bi-directional overpressure shut-off valve.

Disclosed is a valve assembly, including: a valve duct having an upstream end, a downstream end and a duct wall extending from the upstream end to the downstream end; a first conduit extending from a first end at the valve duct to a second end spaced apart from the first end, the first conduit terminating at a valve assembly component; and a washing filter that includes filter media, wherein the filter media extends into the valve duct to remove particles and provide a clean flow to the first conduit.

The washing filter extends from the first end of the conduit into the valve duct.

In addition to one or more of the above aspects of the valve assembly, or as an alternate, the washing filter is jacketless; the washing filter is configured with a <NUM> micrometer filter rating; and the washing filter defines <NUM> square inches (<NUM> sq. cm) of minimum effective filter area.

In addition to one or more of the above aspects of the valve assembly, or as an alternate, the washing filter is corrugated or cylindrical.

The valve assembly further includes: a closure disposed within the valve duct between the upstream and downstream ends, and downstream of the washing filter; a shaft connected to the closure; and a torque motor operatively coupled to the shaft.

In addition to one or more of the above aspects of the valve assembly, or as an alternate, the valve assembly is a butterfly valve and the closure is a plate.

The valve assembly further includes: a housing; a piston assembly disposed within the housing, the piston assembly including a piston chamber, the piston chamber defining a first wall and a second wall that is opposite the first wall, and a transverse wall extending from the first wall to the second wall, the first wall defining a first chamber aperture, the piston assembly including a first piston configured to move in the piston chamber between the first and second walls to define a first pressure chamber between the first piston and the first wall, the first piston being operationally connected to the shaft, wherein the valve assembly component is a flow chamber disposed in the housing, wherein the second end of the first conduit terminates at the at the flow chamber; a second conduit extending from a first end at the flow chamber to a second end at the first chamber aperture; a control member in the flow chamber that is configured to control access from the first conduit into the flow chamber, to thereby control access to the second conduit; and wherein the torque motor is disposed in the housing and configured to control the control member.

Further disclosed is an aircraft system including: an air duct; a valve assembly having one or more of the above disclosed aspects of the valve assembly, wherein the valve duct is coupled to the air duct; and an aircraft system controller configured to control the motor.

Further disclosed is a method of operating a valve assembly according to claim <NUM>, including:
directing a flow through a valve duct; and directing a first portion of the flow into a first end of a first conduit in the valve duct, via a washing filter that includes filter media, wherein the filter media extends into the valve duct, so that particles are removed from the first portion of the flow, and the first portion flows toward a second end of the first conduit at a valve assembly component.

In addition to one or more of the above aspects of the method, or as an alternate, the method further includes: controlling a torque motor to thereby control a shaft, and thereby control a closure in the valve duct.

In addition to one or more of the above aspects of the method, or as an alternate, the flow through the valve duct is air, flowing at greater than at least <NUM> feet per second (<NUM>/s).

In addition to one or more of the above aspects of the method, or as an alternate, the washing filter is jacketless; the washing filter is configured with a <NUM> micrometer filter rating; and the washing filter defines <NUM> square inches of minimum effective filter area.

In addition to one or more of the above aspects of the method, or as an alternate, the washing filter is corrugated or cylindrical.

Aspects of the disclosed embodiments will now be addressed with reference to the figures. Aspects in any one figure is equally applicable to any other figure unless otherwise indicated. Aspects illustrated in the figures are for purposes of supporting the disclosure and are not in any way intended on limiting the scope of the disclosed embodiments. Any sequence of numbering in the figures is for reference purposes only.

As shown in <FIG> and disclosed in greater detail below, the embodiments provide a valve assembly <NUM> (for gases or fluids) with a closure disk <NUM> (or closure <NUM>) that is actuated by utilizing a motor <NUM> to direct flow from Flow Field <NUM> through bleed conduit (first conduit) <NUM> toward a piston assembly <NUM>. To protect the motor <NUM> from flow-borne debris, a washing filter <NUM> is provided. In contrast to prior art filters, the illustrated filter <NUM> is provided such that it is located at the inlet (first end) 130A of the bleed conduit (first conduit) <NUM> and extends into the valve flow field <NUM> defined by the valve duct <NUM>. The flow field <NUM> in the duct <NUM> prevents the buildup of debris that could otherwise clog the filter <NUM>. This is in contrast to prior art systems that where the filter was not in the flow field but, rather, was disclosed outside of it and within the bleed conduit <NUM> (e.g., downstream of the inlet 130A of the first conduit <NUM>). Thus, the embodiments avoid the maintenance and pressure drops associated with clogged filters. The valve assembly <NUM> may be integrated into an aircraft system <NUM>, having a system controller 105A that controls the motor <NUM> via communication/power lines 350A, so that the valve assembly <NUM> may be controlled to deliver a flow to a component 105B.

The assembly <NUM> includes the valve duct <NUM> having an upstream end 110A, a downstream end 110B and a duct wall <NUM> extending from the upstream end 110A to the downstream end 110B. The flow <NUM> that may pass through the duct <NUM> may be, e.g., gas such as engine bleed air or cabin air, depending on the application of the valve assembly <NUM>. The first (bleed) conduit <NUM> extends from the first (or upstream) end 130A (e.g., a bleed inlet) at the valve duct <NUM> to a second end or downstream end 130B spaced apart from the first end 130A. The first conduit <NUM> terminates at a valve assembly component <NUM> after passing through an optional heat exchanger <NUM>. The first conduit <NUM> may bleed off a first portion 115A of the flow <NUM> (e.g., bleed flow).

The washing filter <NUM> (referred to as filter <NUM> for simplicity) includes filter media that <NUM> extends into the valve duct <NUM> to remove particles from a flow <NUM> and provide a clean flow to the first conduit <NUM>. As illustrated, the filter media extends from the first end 130A of the first conduit <NUM>. However, other supplemental elements could be placed between the first end 130A of the first conduit <NUM> and the filter media <NUM>. As shown in <FIG>, the filter <NUM> may be positioned at an angle <NUM> so that its lower end 150B, further from the conduit inlet 130A, is upstream of its upper end 150A closer to/at the conduit inlet 130A. As the filter is in the same valve bore as the disc, it may be arranged in such a way as to avoid contact with the disc. Angling the filter, or including a supplemental element, such as a small section of sealed tube between filter and wall, could be used to make sure the filter packages well. In addition, a filter spaced slightly from the wall with a supplemental element may stay slightly cleaner as the flow velocity is lowest close to the wall.

According to an embodiment, the filter <NUM> is jacketless. That is, there is no external housing to the filter <NUM>. Thus, the filter media is directly engaged by the flow <NUM> through the duct <NUM>. In one embodiment, the filter <NUM> is configured with a <NUM> micrometer filter rating. In one embodiment, the filter <NUM> defines <NUM> square inches (<NUM> sq. cm) of minimum effective filter area. As shown in <FIG>, the filter media may be configured as a pleated (corrugated) cylinder to increase its surface area density, though a circular cross section is within the scope of the disclosure. A cartridge size may be approximately <NUM> inches by ~. <NUM> inches (<NUM> × <NUM>). An estimated airflow washing velocity may be <NUM> ft/s (<NUM>/s) in one embodiment which is sufficient to keep the exposed surface of the filter clean. For air operations, a filter open area may be approximately ~. <NUM> square inches (<NUM> square cm) in one embodiment. Due to the low consumption of bleed air necessary to actuate piston <NUM> and filter density, flow velocity thru the filter is less than flow velocity around the filter, so contaminants will be carried with process air past the filter. The valve portions exposed to flow field <NUM> e.g. closure disc <NUM> are significantly more capable of operating in a contaminated environment than the valve portions within the bleed conduit <NUM> e.g. controller 105a. The size of an embodiment as discussed above is significantly smaller than the current state of the art air filters where the filter is disposed within bleed circuit <NUM> and captures contamination within the filter.

Turning back to <FIG>, according to additional details of the embodiments, the valve assembly <NUM> has a housing <NUM>. The closure <NUM> is disposed within the valve duct <NUM> between the upstream and downstream ends 110A, 110B. A shaft <NUM> is connected to the closure <NUM>. According to an embodiment, the first end 130A of the first conduit <NUM> is upstream of the closure <NUM>.

The piston assembly <NUM> is disposed within the housing <NUM>. The piston assembly <NUM> includes a piston chamber <NUM>. The piston chamber <NUM> defines a first wall 230A and a second wall 230B that is opposite the first wall 230A. A transverse wall 230C extends from the first wall 230A to the second wall 230B. The first wall 230A defines a first chamber aperture 240A.

The piston assembly <NUM> includes one or more pistons generally referenced as <NUM>. That is, a first piston 250A is configured to move in the piston chamber <NUM> between the first and second walls 230A, 230B to define a first pressure chamber 260A between the first piston 250A and the first wall 230A. The first piston 250A is operationally connected to the shaft <NUM>. According to an embodiment, the piston assembly <NUM> includes a second piston 250B disposed in the piston chamber <NUM>, between the first piston 250A and the second wall 230B. This defines a second pressure chamber 260B between the second piston 250B and the second wall 230B and a third pressure chamber 260C between the first and second pistons 250A, 250B. The transverse wall 230C of the piston chamber <NUM> has a third chamber aperture 240C leading to the third pressure chamber 260C.

A rod <NUM> extends between the first and second pistons 250A, 250B so that they move together. The shaft <NUM> is pivotally coupled to the rod <NUM> via pivot link 270A to pivot the closure disk <NUM> from the opened to the closed state. According to an embodiment, the second wall 230B of the piston chamber <NUM> has a second chamber aperture 240B. The first conduit <NUM> includes a first branch <NUM> located intermediate the first and second ends 130A, 130B of the first conduit <NUM>. The first branch <NUM> may direct a segment 115B of the flow portion 115A to it and through the second chamber aperture 240B and into the second pressure chamber 240B.

The valve assembly component <NUM> is a flow chamber <NUM> disposed in the housing <NUM>. The second end 130B of the first conduit <NUM> terminates at the at the flow chamber <NUM>. A second conduit <NUM> extends from a first end 310A at the flow chamber <NUM> to a second end 310B at the first chamber aperture 240A. A control member <NUM> is located in the flow chamber <NUM>. The control member <NUM> may be, e.g., a disk connected to a motor driven shaft <NUM> that is offset from a center of the disk, though this is not intended on limiting the scope of the embodiments. The control member <NUM> is configured to control access of the flow from the first conduit <NUM> into the flow chamber <NUM>. This configuration provides for the control member <NUM> controlling access of the flow 115A to the second conduit <NUM>. In one embodiment, a vent conduit <NUM> may extend from a first end 330A at the flow chamber <NUM> to a second end 330B, exterior to the flow chamber <NUM>. This prevents a buildup of back pressure when the first conduit is closed off and the valve is moved to the normally closed state.

According to an embodiment, the valve assembly <NUM> includes a third conduit <NUM> extending from a first end 340A at the valve duct <NUM> to a second end 340B at the third chamber aperture 240C. According to an embodiment, the third conduit <NUM> includes a vent port 340C located intermediate the first end 340A of the third conduit <NUM> and the third chamber aperture 240C. This prevents a buildup of pressure in the third pressure chamber 260C of the piston chamber <NUM>.

According to an embodiment, the piston chamber <NUM> has a first diameter D1 between the third chamber aperture 240C and the first wall 230A and a second diameter D2 between the third chamber aperture 240C and the second wall 230B. The first diameter D1 is greater than the second diameter D2. Thus, the valve will open relatively easily due to the imbalance of forces between the first and second pistons 250A, 250B.

According to an embodiment, the control member <NUM> is configured to operationally engage the first end 130A of the first conduit <NUM> and the first end 330A of the vent conduit <NUM>. A first state, the second end 130B of the first conduit <NUM> is blocked and the first end 330A of the vent conduit <NUM> is unblocked. In a second state, the second end 130B of the first conduit <NUM> is unblocked and the first end 330A of the vent conduit <NUM> is blocked.

The motor <NUM> is disposed in the housing <NUM> and configured to control the control member <NUM>. The motor <NUM> is a torque motor. The valve assembly <NUM> may be a butterfly valve and the closure <NUM> may be a plate.

According to an embodiment, the heat exchanger <NUM> may be positioned within the first conduit <NUM>, intermediate the first and second ends 130A, 130B. A cooling conduit <NUM> may extend into the housing <NUM> and be coupled to the heat exchanger <NUM>. Thus, the bleed flow 115A may be treated to main operability of components downstream of it, including the motor <NUM>.

In one embodiment, the valve assembly <NUM>, as indicated, may be integrated into an aircraft system <NUM>. The valve duct <NUM> may be coupled to an air duct <NUM> of the aircraft system <NUM>, via upstream and downstream ducts 105A1, 105A1 of the aircraft system <NUM>. The aircraft controller 105A may be configured to control the motor <NUM>, and flow in the valve duct <NUM> may be directed to the aircraft component 105B Uses of air valves would be, e.g., engine bleed air for de-icing of engine and wings, engine bleed air to make starting engine easier, air management systems for conditioning cabin air.

Turning to <FIG>, flowchart shows a method of operating a valve assembly <NUM>. As shown in block <NUM>, the method includes directing a flow <NUM> through a valve duct <NUM>. As shown in block <NUM>, the method includes directing a first portion 115A of the flow <NUM> into a first end 130A of a first conduit <NUM> in the valve duct <NUM>, via a washing filter <NUM> that is connected to the first conduit <NUM> and that includes filter media <NUM>. The media <NUM>, as indicated, extends into the valve duct <NUM>. From this configuration, particles are removed from the first portion 115A of the flow <NUM>, and the first portion 115A flows toward a second end 130B of the first conduit <NUM> at a valve assembly component <NUM>. As indicted above, the valve assembly component <NUM> is a flow chamber <NUM>.

As shown in block <NUM>, the method further includes controlling a torque motor <NUM> to thereby control a shaft <NUM> that controls a closure <NUM> in the valve duct <NUM>. More specifically, the motor <NUM> controls the control member <NUM> in the flow chamber <NUM>. This unblocks the second end 130B of the first conduit <NUM> so that the first portion 11A of flow <NUM> flows into the flow chamber <NUM>. The flow portion 115A thereafter flows into a piston chamber <NUM> via a second conduit <NUM> that is connected between the flow chamber <NUM> and the piston chamber <NUM>. This action moves one or more pistons <NUM> in the piston chamber <NUM> that are connected to a shaft <NUM>. As a result, a closure <NUM> in the valve duct <NUM> is controlled to close.

With the above embodiments, by placing the filter <NUM> into a flow <NUM>, the filter does not need to be sized by considering a contamination holding quantity because it is normally clean. That is, the filter element is directly exposed to flow, and flows out-to-in, and so does not hold contamination as a filter element would if contained within a enclosure, or flowing in-to-out. Therefore any contamination that does not pass through the filter instead continues flowing downstream. Thus, the filter <NUM> can be sized to account for pressure drop and flow path protection. Flow strength to clean the filter can be continuous or intermittent and can be specifically controlled to provide for cleaning bursts of flow.

The filter <NUM> can be a laser drilled or wire mesh screen. The filter <NUM> may be relatively small compared with filters that are required to withstand the buildup of debris over time. Placing the filter at the inlet 130A of the first conduit <NUM> rather than downstream in the first conduit <NUM> decreases complexity of the system, build cost, and avoids maintenance requirements, while enabling a consistent as flow area over time into the first conduit <NUM>.

Claim 1:
A valve assembly, comprising:
a valve duct (<NUM>) having an upstream end, a downstream end and a duct wall extending from the upstream end to the downstream end; a first conduit (<NUM>) extending from a first end at the valve duct (<NUM>) to a second end spaced apart from the first end, the first conduit (<NUM>) terminating at a valve assembly component; and a washing filter (<NUM>) that includes filter media, wherein the filter media extends into the valve duct (<NUM>) to remove particles and provide a clean flow to the first conduit (<NUM>), wherein the washing filter extends from the first end of the conduit into the valve duct (<NUM>); and
a closure (<NUM>) disposed within the valve duct (<NUM>) between the upstream and downstream ends, and downstream of the washing filter; a shaft connected to the closure; and a torque motor operatively coupled to the shaft; a housing (<NUM>); a piston assembly (<NUM>) disposed within the housing, the piston assembly including a piston chamber, the piston chamber defining a first wall and a second wall that is opposite the first wall, and a transverse wall extending from the first wall to the second wall, the first wall defining a first chamber aperture, the piston assembly including a first piston configured to move in the piston chamber between the first and second walls to define a first pressure chamber between the first piston and the first wall, the first piston being operationally connected to the shaft, wherein the valve assembly component is a flow chamber (<NUM>) disposed in the housing, wherein the second end of the first conduit (<NUM>) terminates at the at the flow chamber; a second conduit extending from a first end at the flow chamber to a second end at the first chamber aperture; a control member (<NUM>) in the flow chamber that is configured to control access from the first conduit (<NUM>) into the flow chamber, to thereby control access to the second conduit; and wherein the torque motor disposed in the housing and configured to control the control member.