Patent Description:
Umbrella check valves are one form of check valve that can be used to control the flow of a fluid through a line or device. Specifically, an umbrella check valve enables a fluid to freely flow in one direction of a line or device but is self-sealing so as to prevent the flow of fluid in the opposite direction. Umbrella check valves commonly include an umbrella valve that operates on a seat through which a fluid flows. The seat has a central mounting hole extending therethrough and a spaced apart flow channel extending therethrough. The umbrella valve is made of a resiliently flexible material and includes an annular sealing disk and a mounting stem that centrally projects from a bottom side thereof. The sealing disk is generally domed shaped so that the umbrella valve has the general configuration of an umbrella.

During assembly, the mounting stem of the umbrella valve is pressed into the mounting hole of the seat so that the umbrella valve is secured to the seat by frictional engagement. With the umbrella valve secured to the seat, the sealing disk covers the flow channel with at least the outer perimeter of the umbrella valve biasing in sealed engagement against the seat.

During use, a fluid travels along a flow path and through the flow channel of the seat toward the umbrella valve. Pressure produced by the traveling fluid causes the perimeter edge of the sealing disk to upwardly flex so that the fluid can flow around the umbrella valve and continue along the fluid path. However, as the fluid flow stops, the sealing disk of the umbrella valve resiliently rebounds to again cover the flow channel and seal against the seat. The umbrella valve thus seals the flow channel closed so that the fluid cannot flow in the opposite direction back through the seat.

Proper functioning of umbrella check valves can be critical in some applications. For example, in the pharmaceutical or biopharmaceutical industry, umbrella check valves are used in delivering gas and/or fluids to sterile solutions or suspensions being processed. For example, an umbrella check valve can be used on a gas line that delivers a sparging gas into a bioreactor. The umbrella check valve stops the culture within the bioreactor from flowing through the gas line when sparging is stopped. Failure of the umbrella check valve can result in the culture freely flowing through the gas line and potentially fouling the gas filter and/or gas source. Such fouling can disrupt the production process and potentially result in partial loss or contamination of the culture. Liquid within the gas line can also delay or otherwise disrupt the proper sparging of gas into the bioreactor. Thus, failure of the check valve can disrupt production of the culture or even jeopardize viability.

In other applications, umbrella check valves can be used in dispensing liquid additives into a culture located within a bioreactor. The additive is dispensed by passing through the check valve. In this case, failure of the check valve can cause the culture to flow into the additive upstream of the check valve. This can result in over feeding of the additive into the culture or at least preclude the ability to properly dispense the additive into the culture. Again, failure of the check valve can disrupt production of the culture or even jeopardize viability. Many other problems can also result from the failure of an umbrella check valve. One of the shortcomings of conventional umbrella check valves is that, under certain conditions, such as under a sudden burst of a fluid at high pressure or having a high viscosity, the fluid can dislodge the umbrella valve from the seat and thereby prevent proper functioning of the check valve. As discussed above, the improper functioning of the check valve can result in detrimental consequences in many applications. Accordingly, what is needed in the art are improved umbrella check valves that have a reduced risk of separation of the umbrella valve from the seat during operation and thus have a reduced risk of failure or improper functioning. Other improvements over conventional umbrella check valves is also desired.

Publication <CIT> discloses a flow valve having a sealing member having a first condition for engaging a housing to prevent back flow and a platform for obstructing a flow passage through the flow valve with the platform supporting the sealing member in an out-of-the-way condition to allow fluid to flow through the valve.

Publication <CIT> discloses a valve set including a valve body with a central hole and multiple passages located around the central hole, a tubular portion extending from the valve body, a flexible plate with an insertion inserted to the central hole of the valve body, wherein the flexible plate seals the passages from an underside of the valve body.

Various independent aspects and examples consistent with the present teaching are set out in the following:.

A check valve assembly of the invention comprises:.

In an embodiment of the check valve assembly of the invention the retention plate terminates at an outer perimeter edge, a gap being formed between the outer perimeter edge of the retention plate and the first port fitting so that fluid flowing from the second port fitting to the first port fitting can pass through the gap.

In this embodiment the passage of the tubular stem of the first port fitting has a maximum inner diameter and the outer perimeter edge of the retention plate has a maximum outer diameter, the maximum outer diameter of the retention plate being preferably greater than the maximum inner diameter of the passage of the first port fitting.

In an embodiment of the check valve assembly of the invention the tubular stem of the first port fitting has a first end and an opposing second end with an annular flange outwardly projecting therefrom, the annular flange being secured to the annular sleeve of the base and having a maximum outer diameter that is greater than the maximum outer diameter of the retention plate.

In an embodiment of the check valve assembly of the invention one or more flow paths pass through the plate body between the opposing sides through which fluid can pass.

In this embodiment the one or more flow paths may comprise a plurality of spaced apart flow paths.

Further, in this embodiment the plate body of the retention plate may extend to a perimeter edge, the one of more flow paths may comprise one or more holes that pass through and are encircled by the plate body and/or one or more notches recessed into the perimeter edge of the plate body.

In this embodiment the plurality of legs comprise at least <NUM>, <NUM>, <NUM>, or <NUM> legs.

Further, in this embodiment the tubular stem of the first port fitting has preferably a first end and an opposing second end with an annular flange outwardly projecting therefrom, the annular flange being secured to the annular sleeve of the base.

Each of the plurality of legs preferably terminate at a free end that sits against or is disposed directly adjacent to an inside face of the annular flange of the first port fitting.

In an embodiment of the check valve assembly of the invention the retention plate is more rigid than the umbrella valve.

In an embodiment of the check valve assembly of the invention the passage of the stem of the first port fitting has a first maximum diameter and the passage of the stem of the second port fitting has a second maximum diameter, the first maximum diameter being larger than the second maximum diameter.

In an embodiment of the check valve assembly of the invention the passage of the stem of the first port fitting has a first maximum diameter and the passage of the stem second port fitting has a second maximum diameter, the first maximum diameter being equal to the second maximum diameter.

In an embodiment of the invention the check valve assembly further comprises:.

In this embodiment the maximum first outer diameter of the first flange is preferably equal to the maximum second outer diameter of the second flange.

Each of the above independent aspects of the disclosure may include any of the features, options and possibilities set out in this document, including those under the other independent aspects, and may also include any combination of any of the features, options and possibilities set out in this document.

Various embodiments of the present invention will now be discussed with reference to the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope which is defined by the appended claims.

Before describing the present disclosure in detail, it is to be understood that the terminology used herein is only for the purpose of describing particular embodiments of the present disclosure. Thus, while the present disclosure will be described in detail with reference to specific embodiments, features, aspects, configurations, etc., the descriptions are illustrative. Various modifications can be made to the illustrated embodiments, features, aspects, configurations, etc. without departing from the scope of the invention as defined by the claims.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. While a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present disclosure, only certain exemplary materials and methods are described herein.

Various aspects of the present disclosure, including devices, systems, methods, etc., may be illustrated with reference to one or more exemplary embodiments or implementations.

As used throughout this application the words "can" and "may" are used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Additionally, the terms "including," "having," "involving," "containing," "characterized by," variants thereof (e.g., "includes," "has," and "involves," "contains," etc.), and similar terms as used herein shall be inclusive and/or open-ended, shall have the same meaning as the word "comprising" and variants thereof (e.g., "comprise" and "comprises"), and do not exclude additional, un-recited elements or method steps, illustratively.

Various aspects of the present disclosure can be illustrated by describing components that are coupled, attached, connected, and/or joined together. As used herein, the terms "coupled", "attached", "connected," and/or "joined" are used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being "directly coupled", "directly attached", "directly connected," and/or "directly joined" to another component, no intervening elements are present or contemplated. Thus, as used herein, the terms "connection," "connected," and the like do not necessarily imply direct contact between the two or more elements. In addition, components that are coupled, attached, connected, and/or joined together are not necessarily (reversibly or permanently) secured to one another.

As used herein, directional and/or arbitrary terms, such as "top," "bottom," "front," "back," "left," "right," "up," "down," "upper," "lower," "inner," "outer," "internal," "external," "interior," "exterior," "proximal," "distal" and the like can be used solely to indicate relative directions and/or orientations.

Where possible, like numbering of elements have been used in various figures. In addition, similar elements and/or elements having similar functions may be designated by similar numbering (e.g., element "<NUM>" and element "<NUM>. ") Furthermore, alternative configurations of a particular element may each include separate letters appended to the element number. Accordingly, an appended letter can be used to designate an alternative design, structure, function, implementation, and/or embodiment of an element or feature without an appended letter. Similarly, multiple instances of an element and or sub-elements of a parent element may each include separate letters appended to the element number. In each case, the element label may be used without an appended letter to generally refer to instances of the element or any one of the alternative elements. Element labels including an appended letter can be used to refer to a specific instance of the element or to distinguish or draw attention to multiple uses of the element. However, element labels including an appended letter are not meant to be limited to the specific and/or particular embodiment(s) in which they are illustrated.

The headings used herein are for organizational purposes only. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.

The present disclosure is directed to check valve assemblies containing an umbrella valve that can be used to control the flow of a fluid through a line or device. Specifically, the check valve assemblies enable a fluid to freely flow in one direction of a line or device but are self-sealing so as to prevent the flow of fluid in the opposite direction. The inventive check valve assemblies can be used with a variety of different types of fluids, including a variety of different gases and liquids. The check valve assemblies can also be used in a variety of different applications, such as in the processing of pharmaceutical products, biopharmaceutical products, chemical products, food products and other solutions, suspensions or types of liquids.

Depicted in <FIG> is a perspective view of one embodiment of an inventive check valve assembly 10A incorporating features of the present disclosure. Check valve assembly 10A is configured so that a fluid, such as a gas or liquid, can flow in a direction along arrow <NUM> through check valve assembly 10A but is precluded from flowing in the opposite direction through check valve assembly 10A. In general, check valve assembly 10A includes a first port fitting <NUM>, an opposing second port fitting <NUM>, and a base <NUM> that is disposed therebetween. First port fitting <NUM> is configured to couple with a first fluid line <NUM> while second port fitting <NUM> is configured to couple with a second fluid line <NUM>. Each of fluid lines <NUM> and <NUM> can comprise a flexible tube, such as conventional tubing, or can comprise a rigid tube.

In one embodiment, first fluid line <NUM> can extend to and couple with a container <NUM>. Container <NUM> can comprise a rigid container or a flexible bag made of one or more sheets of polymeric film. In some embodiments, container can comprise a bioreactor and fermentor for growing cultures of cells or microorganisms. By way of example and not by limitation, first fluid line <NUM> may be coupled to a sparger for sparging a gas into a bioreactor or fermentor. In other embodiments, first fluid line <NUM> can be coupled to other types of containers for use in processing biological materials, pharmaceutical products, chemicals, food products, or other materials. Second fluid line <NUM> can couple to a fluid source <NUM>, such as a gas source or liquid source, where the corresponding gas or liquid needs to be delivered into container <NUM>.

As depicted in <FIG> and <FIG>, first port fitting <NUM> comprises an elongated tubular stem 26A that extends between a first end 28A and an opposing second end 30A. Stem 26A bounds a passage 32A that longitudinally extends therethrough. In one embodiment, means are provided for fluid coupling first end 28A of stem 26A to a fluid line, such as first fluid line <NUM>. By way of example, an annular hose barb 34A is disposed on first end 28A so as to encircle and outwardly project from stem 26A. Hose barb 34A is configured so that it can be pressed within first fluid line <NUM> so as to form a liquid tight seal between first port fitting <NUM> and first fluid line <NUM>. Where needed, as discussed further below, a synch, such as a crimp, compression collar, or pull tie, can also be placed around fluid line <NUM> to help produce the liquid tight seal with first port fitting <NUM>.

In other embodiments, two or more hose barbs can be disposed on stem <NUM>. In still other embodiments, hose barb <NUM> can be replaced with annular ribs, rings or other structures formed on stem 26A that will form a liquid tight seal against the interior surface of first fluid line <NUM>. In yet other embodiments of the means for fluid coupling, hose barb <NUM> can be eliminated and replaced with other conventional types of fluid couplers such as a union or aseptic connector.

Continuing with <FIG> and <FIG>, first port fitting <NUM> further includes an annular first mounting flange 36A encircling and radially outwardly projecting from second end 30A of stem 26A. First mounting flange 36A has an inside face 38A that faces towards base <NUM> and an opposing outside face 40A that each extend to an outer perimeter edge 42A. An annular ring 44A projects from inside face 38A toward base <NUM> so as to encircle passage 32A. As discussed below in greater detail, ring 44A is used to engage and help form a liquid tight seal with base <NUM>.

As shown in <FIG>, a stop flange 46A is shown encircling and radially outwardly projecting from stem 26A at a location between hose barb 34A and first mounting flange 36A. Stop flange 46A is used to stop the advancement of first fluid line <NUM> onto stem 26A during assembly and helps to identify that first fluid line <NUM> is properly positioned on first port fitting <NUM>. Specifically, during assembly, first end 28A of first port fitting <NUM> is slid within first fluid line <NUM> until the terminal end of first fluid line <NUM> butts against stop flange 46A. In some embodiments, as mentioned above, a synch, such as a crimp, compression collar, or pull tie, can then be secured and compressed around first fluid line <NUM> at a location between stop flange 46A and hose barb 34A so as to both secure first fluid line <NUM> to first port fitting <NUM> and produce a liquid tight seal therebetween.

It is appreciated that stop flange 46A need not be annular but could comprise a plurality of spaced apart sections that outwardly project from stem 26A. In other embodiments, stop flange 46A can be eliminated. In this embodiment, indicia, such as a marking or groove, could be place on the exterior surface of stem 26A to indicate the proper positioning of the terminal end of first fluid line <NUM>. Alternatively, first mounting flange 36A can be configured to function as the stop flange.

In the depicted embodiment, second port fitting <NUM> has substantially the same configuration as first port fitting <NUM>. As such, all the above discussion with regard to first port fitting <NUM>, including alternatives and uses, are also applicable to second port fitting <NUM>. The exceptions are that second port fitting <NUM> is intended for coupling with second fluid line <NUM> and stop flange 46A is eliminated from second port fitting <NUM>. Like elements between port fitting <NUM> and <NUM> are identified by like reference characters except that the reference characters used on second port fitting <NUM> include the suffix "B.

Continuing with the <FIG> and <FIG>, base <NUM> comprises an annular sleeve <NUM> having an interior surface <NUM> and an opposing exterior surface <NUM> that extend between a first end <NUM> and an opposing second end <NUM>. Sleeve <NUM> encircles an opening <NUM>. Base <NUM> also includes a seat <NUM> that is secured to interior surface <NUM> of sleeve <NUM> so as to extend over opening <NUM>. Seat <NUM> has a first side <NUM> that faces towards first port fitting <NUM> and an opposing second side <NUM> that faces towards second port fitting <NUM>. First side <NUM> and second side <NUM> are typically planar.

Centrally extending through seat <NUM> between opposing sides <NUM> and <NUM> is a mounting hole <NUM>. A plurality of flow channels <NUM> also pass through seat <NUM> between opposing sides <NUM> and <NUM>. Flow channels <NUM> are positioned at locations radially spaced from mounting hole <NUM> so as to be placed around mounting hole <NUM>. Specifically, flow channels <NUM> are spaced apart and are typically located at a common radius from mounting hole <NUM>. In other embodiments, however, it is not necessary that all of flow channels <NUM> be disposed at a common radius from mounting hole <NUM>. Rather, as discussed below in more detail, flow channels <NUM> can be disposed at two or more different radius from mounting hole <NUM>. In the depicted embodiment, eight flow channels <NUM> are formed. However, in other embodiments, it is appreciated that the number of flow channels <NUM> can comprise at least one, two, four, six, eight, ten, or in a range between any two of the foregoing numbers.

Outwardly projecting from second side <NUM> of seat <NUM> so as to encircle mounting hole <NUM> is a stem <NUM>. As better shown in <FIG> and discussed below in more detail, mounting hole <NUM> inwardly constricts as it passes from seat <NUM> through stem <NUM>. In alternative embodiments, stem <NUM> can be eliminated by increasing the thickness of seat <NUM>.

Returning to <FIG> and <FIG>, an annular groove <NUM> is formed on interior surface <NUM> of sleeve <NUM> at first end <NUM> and is configured to receive ring 44A of first port fitting <NUM>. Likewise, an annular groove <NUM> is formed on interior surface <NUM> of sleeve <NUM> at second end <NUM> and is configured to receive ring 44B of second port fitting <NUM>. During assembly, as shown in <FIG>, ring 44A is received within groove <NUM> while ring 44B is received within groove 78A. The structures are then further secured together, such as by adhesive or welding, so as to form a liquid tight seal therebetween. In this assembly, fluid can now flow from second port fitting <NUM>, through flow channels <NUM> and out first port fitting <NUM>.

With continued reference to <FIG> and <FIG>, check valve assembly 10A also includes an umbrella valve 90A and a retention plate 92A. Umbrella valve 90A generally comprises a flexible sealing disk <NUM> having a mounting stem <NUM> projecting therefrom. More specifically, sealing disk <NUM> typically has a circular configuration with an outer surface <NUM> and an opposing inner surface <NUM> that each extend to a perimeter edge <NUM>. Mounting stem <NUM> centrally projects from inner surface <NUM>. Umbrella valve 90A is typically formed as a single, unitary structure and is comprised of a resiliently flexible material such as silicone. Other flexible materials can also be used. The remaining components of check valve assembly 10A, i.e., port fittings <NUM> and <NUM>, base <NUM> and retention plate 92A are typically made of a material that is more rigid than the material that is used to make umbrella valve 90A. These other components <NUM>, <NUM>, <NUM> and 92A are typically made of a plastic such as polycarbonate. Other materials can also be used. The materials are typically chosen for compatibility with planned use, such as stability at intended temperatures, stability when exposed to fluids, ability to be sterilized by radiation, etc..

Sealing disk <NUM> has domed shaped configuration. That is, outer surface <NUM> has a central apex <NUM> and both outer surface <NUM> and inner surface <NUM> slope down, i.e., toward seat <NUM>, and radially away from apex <NUM> to perimeter edge <NUM>. The term "domed shaped," as used in the specification and append claims broad includes both <NUM>-dimension curved, sloping surfaces, such as concave and convex surface, and <NUM>-dimensional linear, sloping surfaces such as conical and frustoconical surfaces. Thus, outer surface <NUM> or a portion thereof can have a conical, frustoconical, <NUM>-dimensional convex curvature, or have other domed configurations. Likewise, inner surface <NUM> or a portion thereof can have a conical, frustoconical, <NUM>-dimensional concave curvature, or have other domed configurations. In the specific embodiment shown in <FIG>, outer surface <NUM> includes a flat platform surface <NUM> located at apex <NUM> domed sealing surface <NUM> that extends from platform surface <NUM> to perimeter edge <NUM>. Although not always required, in the depicted embodiment, a blind hole <NUM> centrally passes through outer surface <NUM> of sealing disk <NUM>, e.g., at apex <NUM>, and into mounting stem <NUM>. Blind hole <NUM> is better shown in <FIG>. Sealing disk <NUM> also typically tapers, i.e., gets thinner, as it extends to perimeter edge <NUM>.

Disposed at a free end of mounting stem <NUM> is an enlarged head <NUM>. Enlarged head <NUM> has an outer diameter that is larger than the minimum inner diameter of mounting hole <NUM> of seat <NUM>. During assembly, as shown in <FIG>, head <NUM> is compressed as it is pushed through mounting hole <NUM>. Once enlarged head <NUM> passes through mounting hole <NUM>, enlarged head <NUM> resiliently expands so as to again be larger than the diameter of mounting hole <NUM>, thereby securing umbrella valve 90A to seat <NUM> of base <NUM>. The constriction of mounting hole <NUM>, as previously discussed, helps to facilitate pressing enlarged head <NUM> through mounting hole <NUM> and also helps to secure umbrella valve 90A to seat <NUM>. However, in other embodiments, mounting hole <NUM> need not be tapered.

Umbrella valve 90A is configured so that in the assembled state, as shown in <FIG>, umbrella valve 90A can be in a relaxed first position wherein at least outer perimeter edge <NUM> of sealing disk <NUM> directly sits and resiliently presses against first side <NUM> of seat <NUM> so as to form a liquid tight seal therebetween. Umbrella valve 90A is also configured so that in the first position, sealing disk <NUM> covers all of flow channels <NUM>. During operation, a fluid travels through second port fitting <NUM> and through flow channels <NUM> of seat <NUM> toward umbrella valve 90A. Pressure produced by the traveling fluid causes umbrella valve 90A to move from the first position, shown in <FIG>, to a second position, as shown in <FIG>. That is, the fluid pressure causes at least perimeter edge <NUM> of sealing disk <NUM> to upwardly flex, i.e., flex away from flow channels <NUM> and seat <NUM>, so that the fluid can flow through flow channels <NUM>, around perimeter edge <NUM> of sealing disk <NUM> and out through first port fitting <NUM>. However, as the fluid flow stops, sealing disk <NUM> of umbrella valve 90A resiliently rebounds back to the first position (<FIG>) so as to again cover flow channels <NUM> and seal against seat <NUM>. Umbrella valve 90A thus seals flow channels <NUM> closed so that the fluid cannot flow in the opposite direction back through seat <NUM>.

Returning to <FIG> and <FIG>, retention plate 92A comprises a plate body <NUM> having a first side <NUM> and an opposing second side <NUM>. In the depicted embodiment, both first side <NUM> and second side <NUM> are planar. However, in alternative embodiments, first side <NUM> and/or second side <NUM> can have a concave, convex or other non-planar configuration. A plurality of flow paths <NUM> pass through plate body <NUM> between opposing sides <NUM> and <NUM>. In the depicted embodiment, three flow paths <NUM> are shown. However, in other embodiments, flow paths <NUM> can be limited to a single flow path or can comprise at least one, two, three, four, six, or eight flow paths or be in a range between any two of the foregoing numbers. Plate body <NUM> extends to a perimeter edge <NUM>. A plurality of legs <NUM> project from first side <NUM> of plate body <NUM> way from second side <NUM>, i.e., towards first port fitting <NUM>. In the embodiment depicted, legs <NUM> are disposed at perimeter edge <NUM>. However, in other embodiments, legs <NUM> can be disposed inward of perimeter edge <NUM>. Centrally projecting from second side <NUM> of plate body <NUM> is an alignment stem <NUM>. Alignment stem <NUM> is configured to be received within blind hole <NUM> of umbrella valve 90A. In the depicted embodiment, alignment stem <NUM> and blind hole <NUM> have complementary tapers to help facilitate alignment and insertion of alignment stem <NUM> into blind hole <NUM>. However, in other embodiments, alignment stem <NUM> and blind hole <NUM> need not be tapered.

During assembly, once umbrella valve 90A is secured to seat <NUM> of base <NUM>, as discussed above, alignment stem <NUM> of retention plate <NUM> is received within blind hole <NUM> of umbrella valve 90A so that second side <NUM> of plate body <NUM> rest directly against outer surface <NUM> of sealing disk <NUM> of retention valve 90A, as shown in <FIG>. More specifically, second side <NUM> of plate body <NUM> rest directly against flat platform surface <NUM> of outer surface <NUM> of sealing disk <NUM>. First port fitting <NUM> and second port fitting <NUM> are then secured to sleeve <NUM> of base <NUM>, as previously discussed. The order of the assembly of the parts can be altered as will be apparent to those skilled in the art. Retention plate 92A is configured so that legs <NUM> either directly contact or are adjacently disposed to inside face <NUM> of first mounting flange <NUM> of first port fitting <NUM>. To help facilitate this alignment, plate body <NUM> is typically formed having a maximum diameter that is larger than a maximum diameter of passage 32A extending through stem 26A of first port fitting <NUM>. However, plate body <NUM> also has a maximum diameter that is typically smaller than the inner diameter of sleeve <NUM> of base <NUM>. As a result, a gap <NUM> is formed between perimeter edge <NUM> of plate body <NUM> and interior surface <NUM> of sleeve <NUM> through which fluid can flow. Likewise, as a result of legs <NUM>, a gap <NUM> is also formed between plate body <NUM> and first port fitting <NUM> through which fluid can flow. Legs <NUM> thus restrict movement of retention plate 92A, i.e., plate body <NUM>, away from umbrella valve 90A and also provide a gap for fluid flow.

During operation, fluid flows through second port fitting <NUM> and through flow channels <NUM> so as to flex umbrella valve 90A to the second position, as shown in <FIG> and previously discussed. Because retention plate <NUM> only sits against platform surface <NUM> of sealing disk <NUM> and does not interact with perimeter edge <NUM> (when in the first position shown in <FIG>), retention plate <NUM> does not interfere with umbrella valve 90A moving between the first and second positions. The fluid then flows around plate body <NUM> by passing through gaps <NUM> and <NUM> and out through first port fitting <NUM>. Again, when the fluid flow stops, umbrella valve 90A resiliently returns back to its first position so as to seal flow channels <NUM> closed. With reference to <FIG>, when umbrella valve 90A is flexed into the second position, all or a majority of outer surface <NUM> of sealing disk <NUM> can press against second side <NUM> of retention plate 92A. Flow paths <NUM> (<FIG> and <FIG>) are formed extending through sealing disk <NUM> so as to help prevent the formation of a vacuum between sealing disk <NUM> and plate body <NUM> of retention plate 92A when umbrella valve 90A is flexed into the second position. A vacuum formed between sealing disk <NUM> and plate body <NUM> could result in umbrella valve 90A remaining in the second position even when fluid flow is stopped, thereby enabling fluid to freely flow in both directions through check valve assembly 10A. Flow paths <NUM> are formed so that one end is covered by sealing disk <NUM> when umbrella valve 90A is in the second position. However, because the opposing end of flow paths <NUM> remain open, fluid can freely flow through flow paths <NUM> and between sealing disk <NUM> and plate body <NUM> so as to prevent the formation of a vacuum therebetween.

Retention plate 92A functions to help retain umbrella valve 90A secured to seat <NUM> to ensure proper operation of check valve assembly 10A. Specifically, without retention plate 92A, under certain conditions, such as under high fluid flow rates or under sudden bursts of high fluid pressure, the fluid pressure can be sufficiently high to force mounting stem <NUM> of umbrella valve 90A out of mounting hole <NUM> so as to dislodge umbrella valve 90A from base <NUM>, i.e., seat <NUM>. Once umbrella valve 90A dislodges from base <NUM>, umbrella valve 90A no longer functions as a one-way check valve. As a result, fluid can more freely flow in either direction between port fittings <NUM> and <NUM> which can result in contamination of the material being processed within container <NUM>. In addition, the failure of check valve assembly 10A can potentially result in fluid leaking out of container <NUM>. However, because retention plate <NUM> is continually held stable against or adjacent to umbrella valve 90A, retention plate <NUM> restricts movement of umbrella valve 90A that could result in dislodging of umbrella valve 90A from base <NUM>, i.e., seat <NUM>, even under elevated flow rates or burst of high fluid pressure. Thus, retention plate <NUM> ensures proper operation of check valve assembly 10A and thereby minimizes loss, contamination, or disruption of production of the fluid being processed within container <NUM>.

It is appreciated that check valve assembly 10A and the components thereof can have a variety of different configurations. For example, depicted in <FIG> is an alternative embodiment of a check valve assembly 10B wherein like elements between check valve assembly 10A and 10B are identified by like reference characters. Check valve assembly 10B is identical to check valve assembly 10A except that check valve assembly 10B includes a modified umbrella valve 90B and a modified retention plate 92B. Retention plate 92B is identical to retention plate 92A except that alignment stem <NUM> has been removed. As such, second side <NUM> of plate body <NUM> is shown as being planar with no projections outwardly extending therefrom. In turn, as depicted in <FIG>, umbrella valve 90B is identical to umbrella valve 90A except that blind hole <NUM> has been removed.

Check valve assembly 10B still functions in the same way as check valve assembly 10A and all of the prior discussions, alternatives and methods as previously discussed with regard to check valve assembly 10A, except regarding the use of alignment stem <NUM>, are also applicable to check valve assembly 10B. That is, although alignment stem <NUM> and blind hole <NUM> are helpful during the assembly of check valve assembly 10A and also help to ensure and maintain proper centering of retention plate 92A on umbrella valve 90A, the centering can also be achieved by sizing retention plate 92B so that legs <NUM> of retention plate 92B hit against first port fitting <NUM> so as to establish and maintain centering of retention plate 92B on umbrella valve 90B during operation. In still other embodiments, it is not necessarily that retention plate 92B be perfectly centered on top of umbrella valve 90B to still perform its intended function, as discussed above. It is also appreciated that retention plate 92B having alignment stem <NUM> removed therefrom, can be used with umbrella valve 90A that has blind hole <NUM> formed thereon. In that case, blind hole <NUM> would simply not receive any structure from retention plate 92B.

Depicted in <FIG> and <FIG> is another alternative embodiment of a check valve assembly 10C incorporating features of the present disclosure. Like elements between check valve assembly 10A and 10C are identified by like reference characters. Check valve assembly 10C is identical to check valve assembly 10A except that check valve assembly 10C includes a modified retention plate 92C. As previously discussed with regard to <FIG> and <FIG>, retention plate 92A was formed so that plate body <NUM> has an outer diameter that is smaller than the inner diameter of sleeve <NUM>. As a result, gap <NUM> (<FIG>) is formed between plate body <NUM> and sleeve <NUM> of base <NUM> through which fluid can flow. In contrast, with reference to <FIG> and <FIG>, plate body <NUM> of retention plate 92C has an outer diameter that is comparable to the inner diameter of sleeve <NUM>. As a result, outer perimeter edge <NUM> of plate body <NUM> can engage directly against interior surface <NUM> of sleeve <NUM>. However, plate body <NUM> of retention plate 92C has a plurality of flow paths <NUM> extending therethrough toward perimeter edge <NUM> which are not covered by umbrella valve 90A when umbrella valve 90A is in the second position. As such, fluid can flow through flow paths <NUM> when umbrella valve <NUM> is in the second position, thereby eliminating the need for gap <NUM>.

In the embodiment shown in <FIG> and <FIG>, flow paths <NUM> are completely encircled by plate body <NUM>. However, in alternative to or in conjunction with flow path <NUM>, a plurality of flow paths <NUM> can also be formed that extend through plate body <NUM> but that intersect with perimeter edge <NUM>. Flow paths <NUM> are thus formed as notches that extend into perimeter edge <NUM>. Again, flow paths <NUM> are not covered by umbrella valve 90A when umbrella valve 90A is in the second position. As such, fluid can flow through flow paths <NUM> when umbrella valve 90A is in the second position, thereby eliminating the need for gap <NUM>.

Retention plate 92C can be secured to sleeve <NUM> of base <NUM> such as by welding, adhesive, press fitting or being sandwiched between portions of first port fitting <NUM> and sleeve <NUM>. Retention plate 92C is positioned and secured so as to rest against or be disposed directly adjacent to outer surface <NUM>/platform surface <NUM> of umbrella valve 90A so as to again ensure no dislodgement of umbrella valve 90A from seat <NUM> of base <NUM>, as discussed above. By securing retention plate 92C to base <NUM>, legs <NUM> (<FIG>) can be eliminated from retention plate 92C. Alternatively, retention plate 92C need not be secured to base <NUM>. In this embodiment, legs <NUM> (<FIG>) can be disposed so as to upstand from first side <NUM> of plate body <NUM> of retention plate 92C so as to rest against first port fitting <NUM>, as previously discussed, thereby again ensuring no dislodgement of umbrella valve 90A from seat <NUM> of base <NUM>. Retention plate 92C can be used with or without alignment stem <NUM> and blind hole <NUM>.

As depicted in <FIG> and <FIG>, check valve assemblies 10A, 10D and 10E are shown. Like elements between check valve assemblies 10A, 10D and 10E are identified by like reference characters. Check valve assemblies 10D and 10E are identical to check valve assembly 10A except that they are formed with different sized port fittings <NUM> and <NUM>. That is, one of the unique benefits of the inventive check valve assemblies is that they have a modular configuration that enables easy assembly of different check valve assemblies having different port fitting configurations depending on the intended application. For example, check valve assembly 10D still includes base <NUM>, umbrella valve 90A and retention plate 92A. However, in contrast to using port fitting <NUM> and <NUM>, check valve assembly 10D includes port fitting 12A and 14A. Port fitting 12A includes the same mounting flange 36A as port fittings <NUM> for coupling with base <NUM>, as previously discussed. However, port fitting 12A includes a stem 26A1 having a smaller inner diameter and outer diameter than stem 26A. As such, stem 26A1 can be used for coupling check valve assembly 10C to a smaller diameter first fluid line <NUM>. To accommodate the use of stem 26A1, a constricting junction <NUM> extends between mounting flange 36A and stem 26A1.

Port fitting 14A is similar to port fitting <NUM> in that it includes mounting flange 36B for coupling with base <NUM>. However, port fitting 14A also includes a stem 26B <NUM> having an inner diameter and outer diameter smaller than stem 26B. Again, the use of stem 26B <NUM> enables check valve assembly 10C to be fluid coupled to a smaller diameter second fluid line <NUM>. It is appreciated that stems 26A1 and 26B1 can be formed having any desired diameter. Thus, check valve assemblies <NUM> can be formed having at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or more different sized stems for coupling with different sized fluid lines. Furthermore, although check valve assemblies 10C and 10D are shown having the first port fitting and the second port fitting each having a stem with the same diameter, it is appreciated that check valve assemblies <NUM> can be formed where the stems of the first port fitting and the second port fitting have different configurations. For example, check valve assembly 10E is formed having first port fitting <NUM> with the large diameter stem 26A and the second port fitting 14B with the small diameter stem 26B1. Other combinations and variations can also be used.

Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems, processes, products, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments.

Claim 1:
A check valve assembly (10A, 10B, 10C, 10D, 10E) comprising:
a first port fitting (<NUM>) having a tubular stem (26A) with a passage (32A) extending therethrough;
a second port fitting (<NUM>) having a tubular stem (26B) with a passage (32B) extending therethrough;
a base (<NUM>) disposed between the first port fitting and the second port fitting, the base comprising an annular sleeve (<NUM>) encircling a seat (<NUM>), the seat having a first side (<NUM>) and an opposing second (<NUM>) side with a central mounting hole (<NUM>) passing therethrough and one or more flow channels (<NUM>) passing therethrough;
an umbrella valve (90A, 90B) comprising a flexible sealing disk (<NUM>) having an outer surface and an opposing inner surface, a mounting stem (<NUM>) extending from the inner surface of the sealing disk and projecting into the mounting hole of the base, an enlarged head (<NUM>) being formed on the free end of the mounting stem so as to be disposed between the seat of the base and the second port fitting, the enlarged head having a diameter larger than a minimum diameter of the mounting hole of the seat,
the sealing disk being movable between a first position wherein at least a portion of the sealing disk sits on the seat of the base so as to cover the one or more flow channels and a second position wherein the sealing disk is resiliently flexed so as to at least partially uncover the one or more flow channels; and
a retention plate (92A, 92B, 92C) disposed between first port fitting and the seat of the base so that the retention plate sits against or adjacent to the outer surface (<NUM>) of the sealing disk, the retention plate comprising a plate body (<NUM>) having a first side (<NUM>) and an opposing second side (<NUM>), the first side of the plate body sitting against or adjacent to the outer surface of the sealing disk, the retention plate further comprising a plurality of legs (<NUM>) projecting from second side of the plate body so that the plurality of legs space the second side of the plate body away from the first port fitting.