Patent Description:
The inventions relate to fluid flow and delivery devices and methods, and more particularly to poppet valves used to control fluid flow and delivery.

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 a sealing portion (e.g., enlarged disc, tapered end) 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.

<CIT> (<NUM>-<NUM>-<NUM>) describes a pressure regulator comprising a regulator body, an upper plate, an adjuster, spring plates, an upper housing, a spring, diaphragms, a stem body and a plug. A surface of a first diaphragm is adjacent a stepped portion of the regulator body and the opposite surface of the first diaphragm is adjacent a first surface of the upper housing such that the first diaphragm is positioned between the upper housing and the regulator body. Similarly, the surfaces of first diaphragms are adjacent respective first surfaces of the lower housings and the opposite surfaces of the first diaphragms are adjacent first surfaces of the upper housings. The first and second diaphragms, the upper and lower housings, and the upper and lower diaphragm rings are added to the pressure regulator to attain any number of lower and upper chambers. Once the desired number of first and second diaphragms, the upper and lower housings, and the upper and lower diaphragms rings have been added to the pressure regulator, a second diaphragm plate is positioned on the stem body and a nut may be tightened, which couples the first and second diaphragms and the upper and lower diaphragms rings together allowing them to move together substantially as a single unit with the stem.

According to an exemplary embodiment of the present disclosure, not encompassed by the claims, a seat carrier subassembly for a valve includes an annular seat carrier body including an annular projection extending radially into a central passage, and an annular plastic seal ring over-molded onto the annular projection, with the annular plastic seal ring defining a seat seal.

According to another exemplary embodiment of the present disclosure, not encompassed by the claims, a valve assembly includes a valve body defining a flow path between an inlet port and an outlet port, an annular seal ring surrounding an axially extending portion of the flow path between the inlet port and the outlet port, and a poppet assembled with the valve body and axially movable between a closed position and an open position. The seal ring interlocks with a projection extending radially into the flow path.

According to another exemplary embodiment of the present disclosure, not encompassed by the claims, a seat carrier subassembly for a valve includes first and second ring components assembled over an O-ring seal, wherein a portion of the O-ring seal is exposed in an inner diameter gap between inner edge portions of the first and second ring components to define a seat seal.

According to another exemplary embodiment of the present disclosure, a poppet subassembly includes a poppet having a central portion disposed between axially extending upper and lower stem portions, with the central portion defining an upward facing radially extending sealing portion and a downward facing radially extending shoulder portion, a retaining clip secured above an enlarged foot portion of the lower stem portion, and a poppet spring disposed around the lower stem portion and captured between the shoulder portion and the retaining clip.

According to another exemplary embodiment of the present disclosure, a pressure regulator includes a valve body, a poppet disposed within the valve body and including an axially extending upper stem portion and a radially extending poppet sealing portion, a loading mechanism assembled with the valve body and operable to apply a downward load force, and a sensing element disposed between the loading mechanism and the poppet to transmit the load force from the loading mechanism to the poppet. A lower end of the sensing element includes a socket receiving an enlarged head portion of the upper stem portion of the poppet, wherein the socket is sized to permit axial movement of the poppet with respect to the sensing element. The pressure regulator further comprises an overtravel spring disposed around the upper stem portion of the poppet and compressed between a shoulder portion of the poppet and an end face of the socket.

According to another exemplary embodiment of the present disclosure, a pressure regulator includes a valve body module having a valve body housing block retaining a poppet and a seat seal, a loading module having a loading block secured adjacent to the venting adapter block and retaining a loading element configured to apply a load force to a sensing member disposed between the loading element and the poppet, and at least one of: a piston module having a piston adapter block secured between the valve body housing block and the loading block and retaining the sensing member in engagement with the poppet, wherein the sensing member comprises a piston; and a venting module having a venting adapter block secured between the valve body housing block and the loading block and defining a vent port in fluid communication with a vent passage in the sensing member. The valve body housing block and the at least one of the piston adapter block and the venting adapter block each include a uniformly sized first assembly interface, and the loading block and the at least one of the piston adapter block and the venting adapter block each include a uniformly sized second assembly interface in mating and sealing engagement with the first assembly interface of the adjacent one of the valve body housing block and the at least one of the piston adapter block and the venting adapter block, such that the valve body housing block is configured to be assembled directly to the loading block by omitting each of the at least one of the piston module and the venting module.

According to another exemplary embodiment of the present disclosure, a pressure regulator includes a valve body retaining a valve seat, a poppet disposed within the valve body and axially movable with respect to the valve seat, a spring loading mechanism assembled with the valve body and operable to apply a downward load force, and a sensing element disposed between the spring loading mechanism and the poppet to transmit the load force from the spring loading mechanism to the poppet. The spring loading mechanism includes a spring housing, a spring element retained in the spring housing and disposed between an upper force adjusting plate and a lower spring bearing plate, and an adjustment handle assembled with the spring housing and including a threaded stem portion in threaded engagement with the upper force adjusting plate. The upper force adjusting plate is rotationally fixed and axially slideable within the spring housing, such that user rotation of the adjustment handle axially moves the upper force adjusting plate to adjust the downward load force.

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 pressure-reducing and back-pressure regulator valve arrangements, the features of the present application may additionally or alternatively be applied to other types of valves, including, for example, user operable regulating valves, shutoff valves, check valves, and relief valves. 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 flow restricting member that is moved relative to an annular seat by longitudinal movement of the stem, and that may, but need not, be movable into sealing engagement with the valve seat. 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.

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. 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, software, hardware, control logic, 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. Parameters identified as "approximate" or "about" a specified value are intended to include both the specified value and values within <NUM>% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present application may, but need not, be to scale, and therefore may be understood as teaching various ratios and proportions evident in the drawings. 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, the inventions instead being set forth in the appended claims. 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.

With reference to <FIG>, in a schematically illustrated exemplary embodiment, a poppet type valve assembly <NUM> includes a valve body <NUM> defining a valve passage <NUM> between inlet and outlet ports <NUM>, <NUM>, and an annular valve seat <NUM> extending around an axially extending central portion <NUM> of the valve passage. A poppet <NUM> is assembled with the valve body <NUM> and includes an axially extending poppet stem <NUM> and a radially extending poppet sealing portion <NUM>. An actuator or loading mechanism <NUM> is assembled with the poppet stem <NUM> to control axial movement of the poppet <NUM> between a closed position, in which the poppet sealing portion <NUM> seals against the valve seat <NUM> (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 <NUM> of the valve passage <NUM>. The actuator <NUM> may be user operable (e.g., manually, pneumatically, or electrically operable) for selective movement of the poppet <NUM>. Alternatively, the actuator <NUM> 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 <NUM> 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.

<FIG> schematically illustrates a pressure-reducing regulator 10a having a regulating mechanism including a sensing element 80a (e.g., a piston or diaphragm) having an upper side subjected to a load force FS applied by a loading mechanism 50a (e.g., a compressed spring or fluid pressurized chamber) for downward biased movement of the poppet 40a. The lower side of the sensing element 80a is subject to the force F of the system fluid, providing for upward movement of the poppet 40a (e.g., by direct attachment or separately driven movement of the poppet) when the system fluid force F exceeds the biasing element load force FS. The load force FS biases the poppet 40a toward an open position away from sealing engagement with the valve seat 32a. When the downstream fluid pressure exceeds a desired pressure, corresponding to the system fluid force F exceeding the biasing element load force FS, the sensing element 80a moves upward to provide for upward movement of the poppet toward a closed position with respect to the valve seat 32a, thereby reducing the outlet pressure. When the downstream fluid pressure is reduced to or below the desired pressure, the biasing element load force FS overcomes the system fluid force F for downward movement of the sensing element 80a to provide for downward movement of the poppet 40a toward the open position.

<FIG> schematically illustrates a back-pressure regulator 10b which, similar to the pressure-reducing regulator 10a of <FIG>, has a regulating mechanism including a sensing element 80b (e.g., a piston or diaphragm) having an upper side subjected to a load force Fs applied by a loading mechanism 50b (e.g., a compressed spring or fluid pressurized chamber) for downward biased movement of the poppet 40b. The lower side of the sensing element 80b is subject to the force F of the system fluid, providing for upward movement of the poppet 40b when the system fluid force F exceeds the loading mechanism load force Fs. The load force FS biases the poppet 40b toward a closed position in sealing engagement with the valve seat 32b. When the upstream fluid pressure exceeds a desired pressure, corresponding to the system fluid force F exceeding the loading mechanism load force Fs, the sensing element 80b moves upward to provide for upward movement of the poppet toward an open position with respect to the valve seat 32b, thereby reducing the inlet or upstream pressure. When the upstream fluid pressure is reduced to or below the desired pressure, the loading mechanism load force FS overcomes the system fluid force F for downward movement of the sensing element 80b to provide for downward movement of the poppet 40b toward the closed position.

Many different regulator valve body, poppet, and seat arrangements may be utilized in a variety of combinations. <FIG> illustrates an exemplary pressure-reducing regulator valve subassembly <NUM> including a regulator valve body <NUM> defining a valve passage <NUM> between inlet and outlet ports <NUM>, <NUM>, and an annular valve seat seal surface <NUM> disposed in an axially extending central cavity <NUM> of the valve body between the inlet and outlet ports. A poppet <NUM> is assembled with the valve body <NUM> and includes an axially extending upper poppet stem <NUM> for engaging (directly or indirectly) the sensing element, and a radially extending poppet sealing portion <NUM>, with the poppet being axially movable between a lower, open position in which the poppet sealing portion is axially spaced from the seat seal surface <NUM>, and an upper, closed position in which the poppet sealing portion is in sealing engagement with the valve seat sealing surface. The outlet port <NUM> is in fluid communication with a sensing interface chamber <NUM> at least partially defined by an upper end of the valve body <NUM>. In such an arrangement, a downward force applied to the poppet <NUM> through the sensing mechanism (described in greater detail below) that exceeds the upward force applied by the outlet fluid pressure moves the poppet toward the lower, open position.

In the illustrated example, the valve body <NUM> includes a body housing <NUM> and a body plug <NUM> assembled (e.g., in threaded engagement) with the central cavity <NUM> of the housing, and the valve seat seal surface <NUM> is disposed on a seat carrier <NUM> retained within the central cavity of the housing.

As shown in <FIG>, the body housing <NUM> may be provided with a support ring <NUM>, sized to support the regulator in an upright position (e.g., on a workbench) prior to installation. The support ring <NUM> may be provided in a flexible plastic (e.g., nylon) to facilitate snap-on (and snap-off) engagement with a lower lip <NUM>-<NUM> on the body housing <NUM>. Upon installation, the support ring <NUM> may be removed or retained with the regulator, for example, as a visual indicator (e.g., color code, text or symbols). In other embodiments, the support ring may provide for attachment of additional hardware or devices. For example, as shown in <FIG>, a heater block <NUM> (or other fixture block) may be secured to the support ring <NUM> using threaded fasteners <NUM> installed through mounting apertures <NUM> in the support ring and threaded into mounting bores <NUM> in the heater block <NUM>.

The exemplary body plug <NUM> includes a central cavity <NUM> that receives a lower stem portion <NUM> of the poppet <NUM>, an upper end face <NUM> that engages the seat carrier <NUM> to secure the seat carrier against a first counterbore <NUM> of the central cavity <NUM>, and one or more apertures <NUM> arranged to align with the valve body inlet port <NUM>, to allow for fluid flow from the inlet port into the body plug cavity <NUM>, and between the poppet sealing portion <NUM> and the valve seat seal surface <NUM> to the outlet port <NUM> when the poppet <NUM> is in an open position. The apertures <NUM> may be circumferentially spaced around the body plug <NUM> to assure alignment of the inlet port <NUM> with at least one of the apertures, regardless of the rotational position of the body plug in the valve body housing <NUM>. The seat carrier <NUM> may be provided with an outer annular groove <NUM> retaining a gasket or O-ring seal <NUM> for sealing engagement with the first counterbore <NUM>. The body plug end face <NUM> may be configured to engage a second counterbore <NUM> in the central cavity <NUM>, for example, to limit axial compression of the seat carrier <NUM>.

As shown, the poppet <NUM> may be provided with an internal passage <NUM> extending from the lower stem portion <NUM> of the poppet to an upper portion of the poppet downstream of the seat seal surface <NUM>, with a gasket seal <NUM> providing a seal between an enlarged lower foot portion <NUM> of the poppet lower stem portion and a narrower base portion <NUM> of the body plug cavity <NUM>, such that when the poppet <NUM> is in the closed position, the inlet or upstream fluid pressure on the poppet is offset by the outlet or downstream fluid pressure. This arrangement may be referred to as a balanced poppet design, which may, for example, provide for reduced seat load, for example, to reduce wear/deformation of the seat seal surface <NUM>. In such an arrangement, a poppet spring <NUM> may be provided in the body plug cavity <NUM>, compressed between the body plug <NUM> and the poppet <NUM> (e.g., at shoulder <NUM>) to provide a consistent closing/sealing force against the poppet, independent of system fluid pressure.

To facilitate assembly of the pressure-reducing regulator valve subassembly <NUM>, the poppet spring <NUM> may be preassembled with the poppet <NUM> as a poppet subassembly, for example, in an uncompressed or partially compressed condition, allowing for initial engagement of the body plug threads with the housing threads without having to compress the spring. Once the body plug <NUM> is partially threaded with the central cavity <NUM>, full threaded installation of the body plug in the central cavity completes the desired compression of the poppet spring <NUM>, with the engagement of the body plug end face <NUM> against the second counterbore <NUM> providing a hard stop for the threaded installation. While many different arrangements may be used to provide a poppet with a pre-assembled spring, in the illustrated embodiment, as more clearly shown in <FIG>, an e-shaped clip or other such retaining clip <NUM> is secured above the enlarged foot portion <NUM> of the lower poppet stem <NUM>, providing a lower bearing surface for the poppet spring <NUM>. The spring <NUM> may, but need not, be pre-compressed or spring loaded between the poppet shoulder <NUM> and the retaining clip <NUM>. The body plug cavity <NUM> may include a shallow annular recess or counterbore <NUM> sized to receive and align the retaining clip <NUM>.

In an exemplary method, to assemble the seat carrier <NUM>, poppet <NUM>, and body plug <NUM> with the valve body housing <NUM>, the seat carrier <NUM> is inserted into the housing through the lower end of the central cavity <NUM>. The poppet <NUM>, with pre-assembled poppet spring <NUM> is installed in the central cavity <NUM>, with the upper poppet stem <NUM> extending through the central bore in the seat carrier <NUM>. The body plug is installed over the lower poppet stem <NUM> and threaded with the valve body housing <NUM> to secure the seat carrier <NUM> against the first counterbore <NUM>, with the body plug counterbore <NUM> engaging the retaining clip <NUM> to move the retaining clip away from the foot portion <NUM> of the lower poppet stem <NUM> and compress the poppet spring <NUM> to the desired compression.

<FIG> illustrates an exemplary back-pressure regulator valve subassembly <NUM> including a regulator valve body <NUM> defining a valve passage <NUM> between inlet and outlet ports <NUM>, <NUM>, and an annular valve seat seal surface <NUM> disposed in an axially extending central cavity <NUM> of the valve body between the inlet and outlet ports. A poppet <NUM> is assembled with the valve body <NUM> and includes an axially extending upper poppet stem <NUM> for engaging (directly or indirectly) the sensing mechanism, and a radially extending poppet sealing portion <NUM>, with the poppet being axially movable between a lower, closed position in which the poppet sealing portion is in sealing engagement with the seat seal surface <NUM>, and an upper, open position in which the poppet sealing portion is axially spaced from the seat seal. The inlet port <NUM> is in fluid communication with a sensing interface chamber <NUM> at least partially defined by an upper end of the valve body housing <NUM>. In such an arrangement, a downward force applied to the poppet <NUM> through the sensing mechanism (described in greater detail below) that exceeds the upward force applied by the inlet fluid pressure moves the poppet toward the lower, closed position.

While a valve body may be provided as a single piece or monolithic component including an integrally formed valve seat, in other embodiments, the valve body may include a multiple component assembly, for example, to facilitate installation and/or replacement of the poppet, the valve seat, or other such components. In the illustrated example, the valve body <NUM> includes a valve housing <NUM> and a body plug <NUM> assembled with (e.g., in threaded engagement) the central cavity <NUM> of the housing, and the valve seat seal surface <NUM> is disposed on a seat carrier <NUM> retained within the central cavity of the housing.

The exemplary body plug <NUM> includes a central cavity <NUM> that receives a lower stem portion <NUM> of the poppet <NUM>, an upper end face <NUM> that engages the seat carrier <NUM> to secure the seat carrier against a first counterbore <NUM> of the central cavity <NUM>, and one or more apertures <NUM> arranged to align with the valve body outlet port <NUM>, to allow for fluid flow from the inlet port <NUM>, passing between the poppet sealing portion <NUM> and the valve seat seal surface <NUM> into the body plug cavity <NUM>, through the aperture(s) <NUM> to the outlet port <NUM> when the poppet <NUM> is in an open position. The apertures <NUM> may be circumferentially spaced around the body plug <NUM> to assure alignment of the outlet port <NUM> with at least one of the apertures, regardless of the rotational position of the body plug in the valve body housing <NUM>. The seat carrier <NUM> may be provided with an annular end face groove <NUM> retaining a gasket/O-ring seal <NUM> for sealing engagement with the first counterbore <NUM>. The body plug end face <NUM> may be configured to engage a second counterbore <NUM> in the central cavity <NUM>, for example, to limit axial compression of the seat carrier <NUM>.

As shown, the poppet <NUM> may be provided with an internal passage <NUM> extending from the lower stem portion <NUM> of the poppet to an upper portion of the poppet upstream of the seat seal surface <NUM>, with a gasket seal <NUM> providing a seal between an enlarged lower foot portion <NUM> of the poppet lower stem portion and a narrower base portion <NUM> of the body plug cavity <NUM>, such that when the poppet <NUM> is in the closed position, the inlet or upstream fluid pressure on the poppet is offset by the outlet or downstream fluid pressure. This arrangement may be referred to as a balanced poppet design, which may, for example, provide for reduced seat load, for example, to reduce wear/deformation of the seat.

In a back-pressure regulator valve subassembly, the seat may further be protected from excessive poppet closing force applied by the sensing mechanism by an overtravel spring, disposed between the sensing mechanism and the poppet sealing portion, allowing for further downward axial travel of the sensing mechanism upon engagement of the poppet sealing portion with the seat seal. According to an exemplary aspect of the present disclosure, a poppet may be interlocked with a bearing member of a sensing mechanism using a joint configured to allow for limited axial movement of the poppet with respect to the sensing mechanism bearing member, with an overtravel spring captured between opposed surfaces of the poppet and the sensing mechanism bearing member. This joint arrangement may facilitate assembly of the poppet with the sensing mechanism.

While many different joint arrangements may be utilized, in an exemplary embodiment, one of the poppet and the bearing member is provided with an enlarged or flanged head portion, and the other of the poppet and the bearing member includes a slotted socket portion that retains the head portion, with an overtravel spring compressed between portions of the poppet and the bearing member, such that the overtravel spring biases the sealing portion of the poppet away from the bearing member. When the load force of the sensing mechanism moves the poppet to the closed position, excess closing forces from the sensing mechanism cause the overtravel spring to be compressed between the poppet and the bearing member, thereby limiting closing forces applied by the poppet to the seat seal.

In the illustrated example, as also shown in <FIG>, an enlarged or flanged head portion <NUM> of the poppet <NUM> is received in a slotted socket portion <NUM> of the sensing mechanism bearing member <NUM>, and an overtravel spring <NUM> is compressed between a lower end face <NUM> of the bearing member and an upper shoulder <NUM> of the poppet <NUM>, such that the overtravel spring <NUM> biases the sealing portion <NUM> of the poppet away from the bearing member. When the load force of the sensing mechanism moves the poppet <NUM> to the closed position, excess closing forces from the sensing mechanism cause the overtravel spring <NUM> to be compressed between the poppet and the bearing member <NUM>, thereby limiting closing forces applied by the poppet to the seat seal surface <NUM>.

In an exemplary method, to assemble the seat carrier <NUM>, poppet <NUM>, and body plug <NUM> with the valve body housing <NUM> of a back-pressure regulator valve arrangement <NUM>, the overtravel spring <NUM> is slipped over the upper poppet stem <NUM>, and the head portion <NUM> of the poppet is inserted into the slotted socket portion <NUM> of the sensing mechanism bearing member <NUM>, such that the overtravel spring <NUM> is compressed between the poppet and the bearing member. The poppet <NUM> is inserted into the housing <NUM> through the upper end of the central cavity <NUM>, and the seat carrier <NUM> is inserted into the housing through the lower end of the central cavity <NUM>. The body plug <NUM> is installed over the lower poppet stem <NUM> and threaded with the valve body housing <NUM> to secure the seat carrier <NUM> against the first counterbore <NUM>.

Many different types of seat carrier assemblies may be utilized, for example, to accommodate different system pressures, temperatures, and fluid/chemical properties. In the exemplary embodiments of <FIG> and <FIG>, the seat carrier <NUM>, <NUM> includes an annular single piece seat <NUM>, <NUM> having a contoured inner diameter defining the seat seal surface <NUM>, <NUM>. The seat carrier <NUM>, <NUM> may be provided in any suitable material, including, for example, plastics such as polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), and polyetheretherketone (PEEK). In the pressure-reducing regulator valve subassembly <NUM>, the seat carrier includes an outer annular groove <NUM> retaining a gasket seal <NUM> for sealing engagement with the first counterbore <NUM>. In the back-pressure regulator valve subassembly <NUM>, the seat carrier <NUM> includes an annular end face groove <NUM> retaining a gasket seal <NUM> for sealing engagement with the first counterbore <NUM>.

In some applications, use of seats and sealing portions of harder materials (e.g., materials having a hardness of at least <NUM> SHORE D), for example, metals (e.g., stainless steel), for example, in high pressure and/or high temperature applications, may result in greater susceptibility to seat leakage, for example, due to seat-seal misalignment, surface inconsistencies, contamination, or wear. Minor leakage, particularly at high pressures, can cause erosion of the sealing surfaces, leading to more significant leakage past the valve seat. 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 disclosure, a valve seat may be provided as an over-molded, overlaid, or otherwise interlocking annular softer material (e.g., having a hardness less than about <NUM> HRM) seal ring that is secured to or retained on a harder (e.g., a hardness greater than about <NUM> HRB) inner circumferential rib, flange, rail, or other such projection protruding into the central portion of the valve passage. The rigid underlying projection allows for the use of a relatively thin (e.g., between about <NUM> and about <NUM> inches) seal ring, thereby minimizing thermal expansion, material flow, and deformation of the softer seal ring material, while providing rigid support to facilitate use in higher pressure (e.g., up to about <NUM> psi) applications.

<FIG> illustrate an exemplary annular seat carrier subassembly <NUM>, similar to the seat carriers <NUM>, <NUM> of <FIG> and <FIG>, including a seat carrier body <NUM> having an inner peripheral annular projection <NUM>, and an annular seal ring <NUM> over-molded, overlaid, or otherwise interlocked with the annular projection. The seal ring <NUM> defines a seat seal surface <NUM> contoured for sealing engagement with the poppet sealing portion (for example, as shown in <FIG> and <FIG>). While a variety of projections may be utilized, in the illustrated embodiment, the projection <NUM> is formed as an annular, circumferentially continuous and generally T-shaped rail including a narrower neck portion and an enlarged head portion shaped to be retained in interlocking engagement with a complementary shaped channel portion <NUM> of the seal ring <NUM>. In other embodiments, the projection may have a different cross-sectional shape, and/or may be circumferentially discontinuous, for example, varying in cross-sectional shape around the circumference, or formed from two or more circumferentially spaced segments.

Similar to the seal rings <NUM>, <NUM> of <FIG> and <FIG>, the seat carrier <NUM> may include an first annular groove <NUM> (e.g., outer annular groove) retaining a gasket seal <NUM> for sealing engagement with a counterbore in a valve body (e.g., with counterbore <NUM> in the pressure-reducing regulator valve subassembly <NUM> of <FIG>) to provide a downward facing seat seal surface <NUM>, and/or a second annular groove <NUM> (e.g., annular end face groove <NUM>) retaining a gasket seal <NUM> for sealing engagement with a counterbore in a valve body (e.g., with counterbore <NUM> in the back-pressure regulator valve subassembly <NUM> of <FIG>) to provide an upward facing seat seal.

While the seal ring may be press fit or otherwise assembled over the projection, in other embodiments, the seal ring <NUM> may be injection molded or over-molded onto the annular projection <NUM>, which may provide for consistent roundness, surface finish, and material thickness of the seal ring. A variety of injection molding methods may be employed. In an exemplary arrangement, injection molding using diaphragm gating to a noncritical location g of the seal ring inner diameter, spaced apart from the contoured sealing surface <NUM>, may prevent injection molding flow lines and any resulting non-uniform shrinkage and inconsistent roundness of the seal ring.

In still other embodiments, additive manufacturing (e.g., 3D printing) may be utilized to form the seal ring over the underlying projection. Examples of additive manufacturing techniques that may be utilized include, for example: laser powder bed fusion (direct metal laser sintering or "DMLS," selective laser sintering/melting or "SLS/SLM," or layered additive manufacturing or "LAM"), electron beam powder bed fusion (electron beam melting or "EBM"), ultrasonic additive manufacturing ("UAM"), or direct energy deposition (laser powder deposition or "LPD," laser wire deposition or "LWD," laser engineered net-shaping or "LENS," electron beam wire deposition).

Any suitable materials may be used to provide adequate sealing performance within the valve. For example, the seal ring may be provided in suitable plastic (e.g., PEEK), and the seal ring retaining projection may be provided in a metal (e.g., stainless steel). The gasket / O-ring seals may be formed from a suitable elastomer (e.g., ethylene propylene diene monomer (EPDM), perfluoro-elastomer, or nitrile).

In other embodiments (not shown), the seal ring retaining projection may be integrally formed with the valve body (e.g., as a protrusion into the valve body channel), thereby eliminating the separate seat carrier component.

In accordance with another aspect of the present disclosure, a valve seat seal may be defined by an elastomeric gasket or O-ring, for example, to provide effective sealing in lower pressure (e.g., less than about <NUM> psi) applications. While an O-ring/gasket seat seal may be carried by the poppet, in other embodiments, a seat carrier arrangement may be configured to securely retain an O-ring gasket seal to provide a seat seal for poppet (e.g., a single piece poppet). In an exemplary embodiment, the seat carrier may include separate first and separate ring components that are assembled (e.g., loosely assembled) over an O-ring seal, with a portion of the O-ring seal being exposed in an inner diameter gap between inner edge portions of the first and second ring components. The limited exposure of the O-ring seal may minimize extrusion, clipping, or other damage to the O-ring during valve actuation.

<FIG> illustrate an exemplary annular seat carrier subassembly <NUM>, similar to the seat carriers <NUM>, <NUM>, <NUM> of <FIG>, <FIG>, and <FIG>, including first and second ring components <NUM>-<NUM>, <NUM>-<NUM> assembled over an O-ring seal <NUM>, with a portion of the O-ring seal being exposed in an inner diameter gap between inner edge portions of the first and second ring components to define a seat seal portion <NUM>. The first and second ring components <NUM>-<NUM>, <NUM>-<NUM> may be sized and configured such that when the seat carrier <NUM> is installed in a regulator valve subassembly (e.g., with the seat carrier secured between a body plug and a counterbore in the valve housing), the first and second ring components compress the O-ring seal <NUM> to squeeze the seat seal portion <NUM> of the O-ring seal through the inner diameter gap <NUM> between the first and second ring components.

In the illustrated embodiment, the first, outer ring component <NUM>-<NUM> includes a radially inward extending flange <NUM> defining an inner counterbore <NUM>, and an axially upward (in the orientation of <FIG>) extending flange <NUM> defining an outer counterbore <NUM>. The second, inner ring component <NUM>-<NUM> includes an outer peripheral portion <NUM> that is seated in the outer counterbore <NUM> of the outer ring component <NUM>-<NUM>, and an axially downward extending flange <NUM> that extends toward the radially inward extending flange <NUM> of the outer ring component to define an annular cavity <NUM> for the O-ring seal and the inner diameter gap <NUM>.

Similar to the seal rings <NUM>, <NUM>, <NUM> of <FIG>, <FIG>, and <FIG>, the seat carrier <NUM> may include a first annular groove <NUM> (e.g., outer annular groove) retaining a gasket seal <NUM> for sealing engagement with a counterbore in a valve body (e.g., with counterbore <NUM> in the pressure-reducing regulator valve subassembly <NUM> of <FIG>) to provide a downward facing seat seal <NUM>, and/or a second annular groove <NUM> (e.g., annular end face groove) retaining a gasket seal <NUM> for sealing engagement with a counterbore in a valve body (e.g., with counterbore <NUM> in the back-pressure regulator valve subassembly <NUM> of <FIG>) to provide an upward facing seat seal.

Any suitable materials may be used to provide adequate sealing performance within the valve. For example, the seat carrier ring component(s) may be provided in a metal (e.g., stainless steel) material, and the gasket / O-ring seals may be formed from a suitable elastomer (e.g., EPDM, perfluoro-elastomer, or nitrile).

In other embodiments (not shown), one of the first and second ring components may be integrally formed with the valve body, thereby eliminating one of the separate seat carrier components.

According to another aspect of the present disclosure, one or more regulator valve subassembly components may be configured to facilitate modular interchangeability of components in a plurality of regulator assemblies, including, for example: different flow regulating arrangements (e.g., pressure-reducing, back-pressure regulating), different types of seat seals (e.g., hard plastic, soft elastomeric), different loading mechanisms (e.g., spring loading and/or dome loading mechanisms), different regulator sensing mechanisms (e.g., diaphragm sensing mechanism, piston sensing mechanism), and other optional features (e.g., self-venting arrangement).

For example, as shown in <FIG> and <FIG>, a valve body (e.g., valve body housing <NUM>/<NUM> and valve body plug <NUM>/<NUM>) may be configured for use with both pressure-reducing and back-pressure style regulators. As shown, a first port <NUM>/<NUM> of the valve body housing <NUM>/<NUM> functions as an inlet port for a pressure-reducing regulator valve (<FIG>) and an outlet port for a back-pressure regulator valve (<FIG>), while a second port <NUM>/<NUM> of the valve body housing functions as an outlet port for the pressure-reducing regulator valve and an inlet port for the back-pressure regulator valve. To accommodate the enlarged head-socket joint of the back-pressure regulator valve arrangement (described in greater detail above), the central cavity <NUM>/<NUM> of the valve body housing <NUM>/<NUM> may be provided with an enlarged upper recess <NUM>/<NUM> sized to receive the slotted socket portion <NUM> and the lower end face <NUM> of the bearing member <NUM>. To guide the upper poppet stem <NUM> of the pressure-reducing regulator valve arrangement, a guide ring <NUM> may be installed in the enlarged upper recess <NUM>/<NUM> to closely receive the upper poppet stem. While many different guide rings may be utilized, in the illustrated embodiment, the guide ring <NUM> includes first and second annular guide ring elements <NUM>, <NUM> that capture an O-ring <NUM> that provides a guiding seal against the upper poppet stem <NUM>. The enlarged upper recess <NUM>/<NUM> and the first guide ring element <NUM> may include mating threads for threaded retention of the guide ring <NUM> in the valve body housing <NUM>. As shown, the valve body housing <NUM>/<NUM> may include a bypass channel <NUM>-<NUM>/<NUM>-<NUM> extending from the second port <NUM>/<NUM> to the sensing interface chamber <NUM>/<NUM> for pressurization of the sensing mechanism in the pressure-reducing regulator valve arrangement.

Using the same valve body housing <NUM>/<NUM> and valve body plug <NUM>/<NUM> for both pressure-reducing and back-pressure regulator arrangements provides a uniform recess, between the first and second counterbores <NUM>/<NUM>, <NUM>/<NUM> for retaining the seat carrier for both arrangements. As shown in <FIG>, <FIG>, <FIG>, and <FIG>, a seat carrier <NUM>/<NUM>, <NUM>, <NUM> may be provided with a first annular groove (e.g., outer annular groove <NUM>/<NUM>, <NUM>, <NUM>) and a second annular groove (e.g., end face annular groove <NUM>/<NUM>, <NUM>, <NUM>) for use in both pressure-reducing and back-pressure regulator valve arrangements. When the seat carrier <NUM>/<NUM>, <NUM>, <NUM> is installed with the seat seal surface <NUM>, <NUM>, <NUM> oriented downward for engagement with the poppet sealing portion <NUM> of a pressure-reducing regulator poppet <NUM> (<FIG>), a gasket/O-ring seal <NUM>, <NUM>, <NUM> is retained in the first annular groove <NUM>/<NUM>, <NUM>, <NUM> for sealing engagement with the first counterbore <NUM>. When the seat carrier <NUM>/<NUM>, <NUM>, <NUM> is installed with the seat seal surface <NUM>, <NUM>, <NUM> oriented upward for engagement with the poppet sealing portion <NUM> of a back-pressure regulator poppet <NUM>, a gasket/O-ring seal <NUM>, <NUM>, <NUM> is retained in the second annular groove <NUM>/<NUM>, <NUM>, <NUM> for sealing engagement with the first counterbore <NUM> (<FIG>). In the back-pressure regulator valve subassembly <NUM>, the seat carrier <NUM> includes an annular end face groove <NUM> retaining a gasket seal <NUM> for sealing engagement with the first counterbore <NUM>.

A diaphragm sensing mechanism, used, for example, in lower outlet pressure applications (e.g., spring loading assemblies used with up to about <NUM> psi outlet pressure) and in applications for which greater accuracy in sensing changes in outlet pressure is desired, may be adapted for use with modular pressure-reducing and back pressure regulating valve arrangements, as described herein.

In the illustrated embodiment of <FIG>, a diaphragm sensing mechanism <NUM>, shown with the pressure-reducing regulator valve subassembly <NUM> of <FIG>, includes a flat, flexible disc of material (e.g., elastomer, plastic, or metal as suitable for the system fluid) forming a diaphragm <NUM> having an outer periphery clamped or secured between body surfaces (e.g., between opposed surfaces of the valve body housing block <NUM> and spring or dome loading housing block, tightened by a threaded screw arrangement). As shown, the diaphragm sensing mechanism <NUM> may include a diaphragm screw or bearing member <NUM> installed through a central opening in the diaphragm <NUM> to provide for more robust engagement between the diaphragm and the poppet <NUM> and loading mechanism (as described below), for example, to protect the diaphragm from damage. In the illustrated example, upper and lower plates <NUM>, <NUM> are secured to the diaphragm screw <NUM> on either side of the diaphragm <NUM> by a nut <NUM>, threaded onto the diaphragm screw, to provide additional support for the diaphragm.

In the illustrated embodiment of <FIG>, a diaphragm sensing mechanism <NUM>, shown with the back-pressure regulator valve subassembly <NUM> of <FIG>, may use the same diaphragm <NUM>/<NUM>, upper and lower plates <NUM>/<NUM>, <NUM>/<NUM>, and nut <NUM>/<NUM> as the diaphragm sensing mechanism <NUM> of <FIG>, except with a diaphragm screw or bearing member <NUM> having a lower portion defining a poppet head retaining socket <NUM> and overtravel spring engaging end face <NUM>, similar to that shown in <FIG> and described above.

A diaphragm sensing mechanism having a larger diaphragm, used, for example, in applications for which still greater accuracy/sensitivity in sensing changes in outlet pressure is desired, may be adapted for use with modular pressure-reducing and back pressure regulating valve arrangements, as described herein.

In the illustrated embodiment of <FIG>, a high sensitivity diaphragm sensing mechanism <NUM>, shown with the pressure-reducing regulator valve subassembly <NUM> of <FIG>, includes an enlarged diaphragm <NUM> having an outer periphery clamped or secured between upper and lower diaphragm shell members <NUM>-<NUM>, <NUM>-<NUM> which may be secured to each other by a threaded screw arrangement, and bolted onto the valve body housing block <NUM> (e.g., through mounting holes in the lower diaphragm shell member). As shown, the diaphragm sensing mechanism <NUM> may include a diaphragm screw or bearing member <NUM> installed through a central opening in the diaphragm <NUM> to provide for more robust engagement between the diaphragm and the poppet <NUM> and loading mechanism (as described below), for example, to protect the diaphragm from damage. In the illustrated example, upper and lower plates <NUM>, <NUM> are secured to the diaphragm screw <NUM> on either side of the diaphragm <NUM> by a nut <NUM>, threaded onto the diaphragm screw, to provide additional support for the diaphragm.

In the illustrated embodiment of <FIG>, a high sensitivity diaphragm sensing mechanism <NUM>, shown with the back-pressure regulator valve subassembly <NUM> of <FIG>, may use the same diaphragm <NUM>/<NUM>, upper and lower plates <NUM>/<NUM>, <NUM>/<NUM>, and nut <NUM>/<NUM> as the diaphragm sensing mechanism <NUM> of <FIG>, except with a diaphragm screw or bearing member <NUM> having a lower portion defining a poppet head retaining socket <NUM> and overtravel spring engaging end face <NUM>, similar to that shown in <FIG> and described above.

A piston sensing mechanism, used, for example, in higher pressure spring loading applications (e.g., about <NUM> psi) and in applications for which greater resistance to damage caused by pressure spikes is desired, may be adapted for use with modular pressure-reducing and back pressure regulating valve arrangements, as described herein.

In the illustrated embodiment of <FIG>, a piston sensing mechanism <NUM>, shown with the pressure-reducing regulator valve subassembly <NUM> of <FIG>, includes an axially elongated piston member <NUM> received in a central piston bore <NUM> of a piston adapter plate or block <NUM> secured between body surfaces (e.g., between opposed surfaces of the valve body housing block <NUM> and spring or dome loading housing block, tightened by a threaded screw arrangement). While many different types of sensing piston members may be used, in the illustrated embodiment, the piston member <NUM> includes a stepped configuration, allowing for adjustment of the fluid driven load applied to the piston by selecting the stepped diameter around which an O-ring seal <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> is provided, to vary the piston upper surface against which the fluid pressure acts. The central piston bore <NUM> of the piston adapter block <NUM> is sized and shaped to accommodate this stepped piston configuration. Further, the lower end of the piston adapter block <NUM> may be shaped to conform with the upper end of the valve housing <NUM>/<NUM>, such that the same valve housing may be used with both the diaphragm sensing mechanism <NUM> and the piston sensing mechanism <NUM>. Additionally, a gasket seal <NUM> may be provided between the valve body housing block <NUM> and the piston adapter block <NUM>.

In the illustrated embodiment of <FIG>, a piston sensing mechanism <NUM>, shown with the back-pressure regulator valve subassembly <NUM> of <FIG>, may use the same piston adapter block <NUM>/<NUM> as the piston sensing mechanism <NUM> of <FIG>, except with a piston member <NUM> having a lower portion defining a poppet head retaining socket <NUM> and overtravel spring engaging end face <NUM>, similar to that shown in <FIG> and described above.

A spring loading mechanism, used, for example, for manual adjustability of the regulator pressure setting, may be adapted for use with modular pressure-reducing and back pressure regulating valve arrangements, with both diaphragm sensing and piston sensing mechanisms, as described herein.

In the illustrated embodiment of <FIG>, a spring loading mechanism <NUM> includes an elastically compressible spring element (e.g., one or more coil springs) <NUM> retained in a spring housing <NUM> assembled with the valve body (e.g., by mounting screws installed through an apertured mounting base <NUM>-<NUM> of the spring housing), and compressed between an upper force adjusting plate <NUM> and a lower spring bearing plate <NUM> to apply a load force against the sensing mechanism bearing member <NUM> (e.g., piston or diaphragm screw). As shown, the diaphragm screws <NUM>, <NUM> and piston members <NUM>, <NUM> of the modular assemblies described above may include a uniform, load engaging upper end portion <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, to accommodate use of the same spring loading mechanism <NUM> with any of the modular pressure-reducing and back pressure regulating valve arrangements (with both diaphragm sensing and piston sensing mechanisms) described herein.

The force adjusting plate <NUM> may be adjusted (e.g., raised or lowered) to adjust the amount of spring force applied to the sensing mechanism bearing member <NUM> through the spring bearing plate <NUM>. While many different spring adjusting mechanisms may be utilized, in the illustrated example, a knob handle <NUM> is assembled with the spring housing <NUM> and secured with a threaded stem <NUM>, such that the handle and threaded stem are rotatable to drive the rotationally fixed force adjusting plate <NUM> up and down for adjusting the compression on the spring <NUM>. The force adjusting plate <NUM> is rotationally fixed by a set screw <NUM> (or other suitable projection) on the plate, which rides in a vertical slot <NUM> in the spring housing <NUM>, with the slot sized to provide desired upper and lower limits for the force adjusting plate. A cover panel <NUM> may installed in the slot <NUM>, for example, to block debris, moisture or other contaminants.

A diaphragm sensing dome loading arrangement, used, for example, for remote adjustability of the regulator pressure setting, may be adapted for use with modular diaphragm sensing pressure-reducing and back pressure regulating valve arrangements.

In the illustrated embodiment of <FIG>, a dome loading mechanism <NUM> includes a dome housing <NUM> assembled with the valve body (e.g., by mounting screws) to define a dome chamber <NUM>, and including a pressurization port <NUM> for supplying a pressurized fluid at a set pressure (e.g., from a secondary pressure regulator) to the dome chamber, to apply a corresponding load force against the diaphragm <NUM> of a diaphragm sensing mechanism <NUM> (e.g., the pressure-reducing regulator diaphragm sensing mechanism <NUM> of <FIG>, or the back-pressure regulator diaphragm sensing mechanism <NUM> of <FIG>).

A piston sensing dome loading arrangement, used, for example, for remote adjustability of the regulator pressure setting, may be adapted for use with modular piston sensing pressure-reducing and back pressure regulating valve arrangements.

In the illustrated embodiment of <FIG>, a dome loading mechanism <NUM> includes upper and lower dome housing shell members <NUM>-<NUM>, <NUM>-<NUM> assembled with the valve body (e.g., by mounting screws) to define a dome chamber <NUM>, and a dome loading diaphragm <NUM>, having an outer periphery captured between the upper and lower shell members, with a diaphragm screw <NUM> installed through a central opening in the dome loading diaphragm and positioned to engage the upper end portion <NUM> of the sensing element bearing member <NUM> (e.g., piston member <NUM>, <NUM> of <FIG>). In the illustrated example, support plates <NUM>-<NUM>, <NUM>-<NUM> are secured to the diaphragm screw <NUM> above and below the dome loading diaphragm <NUM> by a nut <NUM>, to provide additional support for the diaphragm. The upper dome housing shell member <NUM>-<NUM> includes a pressurization port <NUM> for supplying a pressurized fluid at a set pressure (e.g., from a secondary pressure regulator) to the dome chamber, to apply a corresponding load force against the dome loading diaphragm <NUM> to move the diaphragm screw <NUM> against the piston member <NUM> of a piston sensing mechanism <NUM> (e.g., the pressure-reducing regulator piston sensing mechanism <NUM> of <FIG>, or the back-pressure regulator diaphragm sensing mechanism <NUM> of <FIG>).

A pressure regulator may be provided with a self-vent feature configured to reduce outlet pressure in a pressure-reducing regulator when the regulator set point is decreased and there is no flow through the regulator. The self-vent feature may include a vent passage through the sensing element (e.g., through the diaphragm screw of a diaphragm sensing element, or through the piston member of a piston sensing element) and a vent passage through the regulator valve body. According to an aspect of the present disclosure, a venting adapter block or plate may be assembled with a regulator valve body, in combination with the use of the vented sensing element, to provide this self-vent feature.

In the illustrated embodiment of <FIG>, a vented diaphragm sensing mechanism <NUM> includes a flat, flexible disc of material (e.g., elastomer, plastic, or metal as suitable for the system fluid) forming a diaphragm <NUM> having an outer periphery clamped or secured between opposed surfaces of the valve body housing block <NUM> and a venting adapter block <NUM> mounted between the valve body housing block and the load mechanism housing <NUM> (e.g., spring housing or dome housing), for example, by a threaded screw arrangement. As shown, the vented diaphragm sensing mechanism <NUM> may include a vented diaphragm screw <NUM> installed through a central opening in the diaphragm <NUM>, which includes a vent passage <NUM>-<NUM> extending from a lower end face of the diaphragm to a mid-portion of the diaphragm screw, in alignment with a cavity <NUM> in the venting adapter block <NUM>, and in fluid communication with a vent port <NUM> in the venting adapter block <NUM>. The vent port <NUM> may be threaded for connection to a fluid line for containment and/or analysis of the vented fluid. The vented diaphragm screw <NUM> may include a plastic (e.g., PEEK) relief seat <NUM>-<NUM> to facilitate sealing engagement with the upper poppet stem <NUM> at pressures below the set point of the regulator.

In the illustrated embodiment of <FIG>, a vented piston sensing mechanism <NUM> includes a piston member <NUM> received in a central piston bore <NUM> of a piston adapter block or plate <NUM>, with an upper portion of the piston member received through a central bore of a venting adapter block <NUM>. The piston adapter plate <NUM> and the venting adapter block <NUM> are secured together between the valve body housing block <NUM> and the load mechanism housing <NUM> (e.g., spring housing or dome housing), for example, by a threaded screw arrangement. As shown, the vented piston sensing mechanism <NUM> may include a vented piston member <NUM> installed having a vent passage <NUM>-<NUM> extending from a lower end face of the piston member to a mid-portion of the piston member, in alignment with a cavity <NUM> in the venting adapter block <NUM>, and in fluid communication with a vent port <NUM> in the venting adapter block. The vent port <NUM> may be threaded for connection to a fluid line for containment and/or analysis of the vented fluid. The vented diaphragm screw <NUM> may include a plastic (e.g., PEEK) relief seat <NUM>-<NUM> to facilitate sealing engagement with the upper poppet stem <NUM> at pressures below the set point of the regulator.

For many of the exemplary features and embodiments described herein, regulator components may be adapted for use in multiple regulator arrangements, for example, to reduce to number of components required to construct a variety of regulators. For example, as described herein, a modular regulator valve body housing may be configured for use in both pressure-reducing and back-pressure regulator assemblies (e.g., by installing a guide ring in the valve body cavity to support the upper poppet stem of the pressure-reducing regulator valve arrangement, and by selectively orienting the seat carrier to provide a downward facing seat seal for pressure-reducing regulator assemblies and an upward facing seat seal for back-pressure regulator assemblies). Additionally or alternatively, a modular regulator valve body housing may be configured for use with both diaphragm sensing and piston sensing arrangements (e.g., by assembling a piston adapter block or plate with the valve body housing to accommodate the piston sensing arrangement). Additionally or alternatively, a modular regulator valve body housing may be configured for use as both a non-venting and a self-venting assembly (e.g., by assembling a vent adapter block with the valve body housing, along with installation of a vented piston member / diaphragm screw, to provide self-venting functionality).

<FIG> illustrate an exemplary piston-sensing, self-venting, spring loading pressure-reducing regulator assembly <NUM>-<NUM> including a valve body module <NUM> having a valve body housing block <NUM> and plug <NUM> retaining or accommodating a pressure reducing poppet <NUM> and seat <NUM> arrangement, a piston module <NUM> including a piston adapter block <NUM> retaining or accommodating a piston sensing member <NUM> in engagement with the poppet, a self-venting module <NUM> including a venting adapter block <NUM> defining a vent port <NUM> in fluid communication with a vent passage <NUM> in the piston sensing member, and a spring loading module <NUM> including a loading block <NUM> retaining a spring loading mechanism (e.g., the spring loading mechanism shown in <FIG> and described above). The modular assembly blocks <NUM>, <NUM>, <NUM>, <NUM> are provided with aligned holes <NUM>, <NUM>, <NUM>, <NUM> (e.g., spaced around an outer periphery, as shown) to receive elongated bolts <NUM> securing the blocks together as an assembly.

To accommodate different modular arrangements in which one or both of the piston module <NUM> and self-venting module are excluded, uniform mating/sealing arrangements may be provided between the stacked module blocks <NUM>, <NUM>, <NUM>, <NUM>, such that the regulator assembly may be converted to or otherwise provided as:.

A variety of uniform first and second block assembly interfaces may be used for uniform mating and sealing engagement between the adjacent blocks. In an exemplary embodiment, as shown in <FIG>, the valve body housing block <NUM>, the piston adapter block <NUM>, and the venting adapter block <NUM> are each provided with a first assembly interface including a uniformly sized upper trepan seal groove <NUM>, <NUM>, <NUM> recessed from an upper end face counterbore <NUM> or groove <NUM>, <NUM> to accommodate an annular gasket seal <NUM>, <NUM>, <NUM>. The piston adapter block <NUM>, the venting adapter block <NUM>, and the loading block <NUM> each include a corresponding second assembly interface including a uniformly sized lower annular shoulder <NUM> or rib <NUM>, <NUM>, received in the corresponding counterbore <NUM> or groove <NUM>, <NUM> to sealingly compress the annular gasket seal <NUM>, <NUM>, <NUM>.

As shown in <FIG> and <FIG>, the diaphragm sensing assemblies <NUM>-<NUM>, <NUM>-<NUM> may include a diaphragm <NUM> having an outer periphery (e.g., flange) <NUM> that is compressed between the trepan seal groove and the boss/rib (e.g., in combination with or in place of the gasket seal <NUM>) to effect a seal between the valve body housing block <NUM> and the diaphragm <NUM>, and between the valve body housing block and the adjacent venting adapter block (in <FIG>) or loading block (in <FIG>).

Additionally, alternate loading modules (e.g., a dome loading module as shown in <FIG>, or a high sensitivity spring/dome loading module as shown in <FIG>, and <FIG>) may be provided with a similar lower annular boss or rib for assembly with the same valve body housing, piston adapter, and venting adapter blocks <NUM>, <NUM>, <NUM>.

Referring to <FIG>, the exemplary pressure reducing regulator valve body module <NUM> includes a guide ring <NUM> (e.g., similar to the guide ring <NUM> described above) installed in an enlarged upper recess <NUM> of the valve body housing block <NUM> to closely receive the upper poppet stem of the pressure reducing poppet <NUM>. As shown in <FIG>, to convert or otherwise provide the regulator assembly as a back pressure regulator assembly <NUM>-4a, the guide ring <NUM> may be removed so that the enlarged upper recess <NUM> of the valve body housing block <NUM> may accommodate the larger upper poppet stem of a back pressure poppet 2130a, installed in combination with a back pressure seat 2140a and diaphragm backpressure subassembly 2250a.

Claim 1:
A pressure regulator (<NUM>-<NUM>) comprising:
a valve body module (<NUM>) including a valve body housing block (<NUM>) retaining a poppet (<NUM>) and a seat seal;
a loading module (<NUM>) including a loading block (<NUM>) retaining a loading element configured to apply a load force to a sensing member disposed between the loading element and the poppet;
a piston module (<NUM>) including a piston adapter block (<NUM>) secured to the valve body housing block and retaining the sensing member in engagement with the poppet, the pressure regulator being characterised in that the sensing member comprises a piston (<NUM>) and the piston adapter block includes a piston bore retaining a stepped fluid driven portion of the piston; and the pressure regulator further comprises:
a venting module (<NUM>) including a venting adapter block (<NUM>) secured between the piston adapter block and the loading block and defining a vent port (<NUM>) in fluid communication with a vent passage (<NUM>) in the sensing member;
wherein the piston adapter block and the venting adapter block each include a uniformly sized first assembly interface, and the loading block and the venting adapter block each include a uniformly sized second assembly interface in mating and sealing engagement with the first assembly interface of the adjacent one of the piston adapter block and the venting adapter block, such that the piston adapter block is configured for assembly directly to the loading block after removing the venting module from between the piston adapter block and the loading block.