U.S. patent application number 10/005484 was filed with the patent office on 2002-07-04 for media control valve.
Invention is credited to Kimmel, Joshua J., Nguyen, Phuong T., Popovits, Brian, Thompson, Robert E..
Application Number | 20020083981 10/005484 |
Document ID | / |
Family ID | 24851718 |
Filed Date | 2002-07-04 |
United States Patent
Application |
20020083981 |
Kind Code |
A1 |
Thompson, Robert E. ; et
al. |
July 4, 2002 |
Media control valve
Abstract
The present invention is related to valves for the controlling
the flow of media. For example, the valves of the present invention
may control the flow of solid media into a fluid stream. More,
specifically, the valves of the present invention may be used to
control the flow of a blasting media into an air stream as part of
a blasting apparatus for treatment of a surface. In one embodiment,
the media control valve of the present invention includes a valve
body having a media inlet and a media outlet. A housing is
connected to the valve body. A plunger is positioned within the
valve body and is connected to a piston positioned within the
housing. A base is connected to the valve body such that it
communicates with the media outlet. The media control valve of this
embodiment may further include a sleeve disposed between the valve
body and the plunger. This sleeve may contain a media opening. In
some embodiments of the media control valve of the present
invention, the media opening has a first portion proximate to the
media outlet and a second portion distal to the media outlet, the
second portion being broader than the first portion. In other
embodiments of the invention, the piston includes a contaminant
isolation region.
Inventors: |
Thompson, Robert E.;
(Sugarland, TX) ; Kimmel, Joshua J.; (Houston,
TX) ; Popovits, Brian; (Livermore, CA) ;
Nguyen, Phuong T.; (Richmond, TX) |
Correspondence
Address: |
WOLF GREENFIELD & SACKS, PC
FEDERAL RESERVE PLAZA
600 ATLANTIC AVENUE
BOSTON
MA
02210-2211
US
|
Family ID: |
24851718 |
Appl. No.: |
10/005484 |
Filed: |
November 8, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10005484 |
Nov 8, 2001 |
|
|
|
09709894 |
Nov 10, 2000 |
|
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Current U.S.
Class: |
137/544 |
Current CPC
Class: |
Y10T 137/8225 20150401;
B24C 7/0046 20130101; F16K 31/1221 20130101; Y10T 137/794 20150401;
F16K 3/246 20130101 |
Class at
Publication: |
137/544 |
International
Class: |
B01D 001/00 |
Claims
What is claimed is:
1. A media control valve, comprising: a valve body having a media
inlet and a media outlet; a plunger positioned within the valve
body; a sleeve positioned within the valve body; a media opening in
the sleeve having a first portion proximate to the media outlet and
a second portion distal to the media outlet, wherein the second
portion is broader than the first portion; a housing connected to
the valve body; a piston positioned within the housing and
connected to the plunger; and a base connected to the valve body in
communication with the media outlet.
2. The valve of claim 1, wherein the base comprises a unitary
structure including a fluid passage and an attachment mechanism
adapted to attach the base to the valve body.
3. The valve of claim 1, wherein the base comprises a fluid passage
and a flow sleeve within the fluid passage.
4. The valve of claim 3, wherein the flow sleeve is comprised of a
wear resistant material.
5. The valve of claim 3, wherein the flow sleeve is comprised of a
chemically resistant material.
6. The valve of claim 1, wherein the piston comprises a contaminant
isolation region.
7. The valve of claim 6, wherein the piston is convex in the
direction of the valve body.
8. The valve of claim 1, further comprising at least one seal
positioned between the plunger and the valve body adapted to resist
the passage of one of media, fluid, contaminants, and combinations
thereof between the valve body and the housing.
9. The valve of claim 8, comprising three seals between the plunger
and the valve body.
10. The valve of claim 9, wherein the three seals are constructed
as a unitary piece.
11. The valve of claim 1, wherein the housing comprises an exhaust
chamber including a vent.
12. The valve of claim 11, wherein the vent comprises a filter.
13. The valve of claim 12, wherein the filter is adapted to filter
particles greater than about 20 microns in diameter.
14. The valve of claim 1, wherein the valve body and the housing
comprise two distinct structures adapted to be joined together.
15. The valve of claim 14, wherein the valve body and housing
comprise a mating structure.
16. The valve of claim 1, further comprising a metering
indicator.
17. The valve of claim 16, further comprising a spring within the
housing and a spring retainer.
18. The valve of claim 17, wherein the spring retainer includes a
marking corresponding to the degree to which the valve is open.
19. The valve of claim 1, further comprising a valve seat.
20. The valve of claim 19, wherein the valve seat is constructed of
an elastomer.
21. The valve of claim 1, further comprising means for providing a
gentle seal.
22. A valve, comprising: a body and an outlet; an opening in the
body having a first portion proximate to the outlet and a second
portion distal to the outlet, wherein the second portion is broader
than the first portion; a closing member positioned within the body
so as to selectively cover the opening.
23. A valve, comprising: a body; a closing member positioned within
the body; a housing; a piston within the housing, connected to the
closing member and having a contaminant isolation region.
24. A media control valve, comprising: a valve body having a media
inlet and a media outlet; a plunger positioned within the valve
body; a sleeve positioned within the valve body; a media opening in
the sleeve; a housing connected to the valve body; a piston having
a contaminant isolation region positioned within the housing and
connected to the plunger; and a base connected to the valve body in
communication with the media outlet.
25. The valve of claim 24, wherein the base comprises a unitary
structure including a fluid passage and an attachment mechanism
adapted to attach the base to the valve body.
26. The valve of claim 24, wherein the base comprises a fluid
passage and a flow sleeve within the fluid passage.
27. The valve of claim 26, wherein the flow sleeve is comprised of
a wear resistant material.
28. The valve of claim 26, wherein the flow sleeve is comprised of
a chemically resistant material.
29. The valve of claim 24, wherein the media opening comprises a
first portion proximate to the media outlet and a second portion
distal to the media outlet and wherein the second potion is broader
than the first portion.
30. The valve of claim 24, wherein the piston is convex in the
direction of the valve body.
31. The valve of claim 24, further comprising at least one seal
between the plunger and the valve body adapted to resist the
passage of one of media, fluid, contaminants, and combinations
thereof between the valve body and the housing.
32. The valve of claim 24, comprising three seals positioned
between the plunger and the valve body.
33. The valve of claim 32, wherein the three seals are constructed
as a unitary piece.
34. The valve of claim 24, wherein the housing comprises an exhaust
chamber including a vent.
35. The valve of claim 34, wherein the vent comprises a filter.
36. The valve of claim 35, wherein the filter is adapted to filter
particles greater than about 20 microns in diameter.
37. The valve of claim 24, wherein the valve body and the housing
comprise two distinct structures adapted to be joined together.
38. The valve of claim 37, wherein the valve body and housing
comprise a mating structure.
39. The valve of claim 24, further comprising a metering
indicator.
40. The valve of claim 39, further comprising a spring within the
housing and a spring retainer.
41. The valve of claim 40, wherein the spring retainer includes a
marking corresponding to the degree to which the valve is open.
42. The valve of claim 24, further comprising a valve seat.
43. The valve of claim 42, wherein the valve seat comprises an
elastomer.
44. The valve of claim 24, further comprising means for providing a
gentle seal.
45. A media control system comprising: a media vessel; an air flow
path; a media flow path having a substantially linear axis and
including a media inlet connected to the media vessel and a media
outlet connected to the media flow path; and a media control valve
positioned on the media flow path.
46. The media control system of claim 45, wherein the substantially
linear axis is substantially perpendicular with respect to a
surface upon which the media control system rests.
47. The media control valve of claim 45, wherein the substantially
linear axis is substantially perpendicular to the axis of the air
flow path.
48. A media control valve comprising: a valve body comprising a
media inlet and a media outlet; means for providing a gentle seal
positioned within the valve body; a sleeve positioned within the
valve body; a media opening in the sleeve; a housing connected to
the valve body; and a base connected to the valve body and in
communication with the media outlet.
49. The media control valve of claim 46, further comprising an
elastomeric valve seat.
Description
[0001] This patent application is a continuation-in-part
application and claims priority to U.S. Ser. No. 09/709,894, filed
Nov. 10, 2000 and entitled MEDIA CONTROL VALVE.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention is related to media control and, more
specifically, media control valves used to control the flow of a
media into a fluid stream as part of an apparatus for treatment of
a surface.
[0004] 2. Description of the Related Art
[0005] A typical media control valve is disclosed in U.S. Pat. No.
3,476,440 ("the '440 patent"), which is hereby incorporated by
reference in its entirety. The valve of the '440 patent is attached
to a media vessel and controls the flow of the media from the media
vessel into a conduit containing a fluid stream. This conduit
terminates in a nozzle. Fluid and media pass through the nozzle at
high speed and are typically used to treat surfaces.
[0006] Other uses for media control valves have been proposed. For
example, U.S. Pat. No. 5,810,045 ("the '045 patent") discloses a
valve for introducing particulate materials into a high-pressure
air stream and suggests several uses for this valve. For example,
the '045 patent suggests that the valve may be used for purposes
such as introducing fluid catalytic cracking catalyst particles
into fluid catalytic cracking units used to crack and reform
various petroleum based products, introducing particulate catalysts
into other kinds of chemical processes, and spraying particulate
ingredients on adhesive substrates as part of various manufacturing
processes.
[0007] Various improvements to the basic media control valve have
been proposed. For example, U.S. Pat. Nos. 5,407,379 ("the '379
patent") and 5,401,205 ("the '205 patent") disclose a media control
valve having a media passage between the media control valve and
the conduit. The media passage converges into a slot-shaped outlet
in the conduit so as to reduce the perimeter of the outlet placed
perpendicular to air flow and consequently reduce turbulence as air
passes across the outlet. The media control valve disclosed in the
'205 and '379 patents is particularly useful in metering and
dispensing sodium bicarbonate media.
[0008] The '045 patent, discussed previously, also discloses a
modification of the original media control valve, including the use
of multiple seals around a plunger of the valve with an exhaust
therebetween to remove any contaminants that breach the seals.
SUMMARY
[0009] According to one embodiment of the present invention, a
media control valve is provided including a valve body having a
media inlet and a media outlet, and a plunger and sleeve positioned
within the valve body. The media control valve also includes a
media opening in the sleeve having a first portion proximate to the
media outlet and a second portion distal to the media outlet,
wherein the second portion is broader than the first portion. The
media control valve further includes a housing connected to the
valve body, a piston positioned within the housing and connected to
the plunger, and a base connected to the valve body in
communication with the media outlet.
[0010] According to another embodiment of the present invention, a
valve is provided including a body having an opening and an outlet.
The opening in the outlet includes a first portion proximate to the
outlet and a second portion distal to the outlet, wherein the
second portion is broader than the first portion. The valve further
includes a closing member positioned within the body so as to
selectively cover the opening.
[0011] According to another embodiment of the present invention, a
valve is provided including a body and a closing member positioned
within the body. The valve also includes a housing and a piston
within the housing. The piston is connected to the closing member
and has a contaminant isolation region.
[0012] According to another embodiment of the present invention, a
media control valve is provided including a valve body having a
media inlet and a media outlet, and a plunger and sleeve positioned
within the valve body. The media control valve also includes a
media opening in the sleeve, a housing connected to the valve body,
a piston having a contaminant isolation region positioned within
the housing and connected to the plunger and a base connected to
the valve body in communication with the media outlet.
[0013] According to another embodiment of the present invention, a
media control system is provided including a media vessel, an air
flow path, a media flow path, and a media control valve positioned
on the media flow path. The media flow path has a substantially
linear axis and includes a media inlet connected to the media
vessel and a media outlet connected to the media flow path.
[0014] According to another embodiment of the present invention, a
media control valve is provided including a valve body comprising a
media inlet and a media outlet, and means for providing a gentle
seal positioned within the valve body. The valve also includes a
sleeve positioned within the valve body, a media opening in the
sleeve, a housing connected to the valve body, and a base connected
to the valve body and in communication with the media outlet.
BRIEF DESCRIPTION OF DRAWINGS
[0015] The foregoing and other advantages of the present invention
will be more fully appreciated with reference to the following
drawings in which:
[0016] FIG. 1 is a diagram of a blasting system incorporating the
media control valve of the present invention;
[0017] FIG. 2 is a cross-sectional side view of a media control
valve according to an aspect of the present invention;
[0018] FIG. 3 is an exploded, elevational view of the valve shown
in FIG. 2;
[0019] FIG. 4 is a side elevational view of a sleeve according to
one embodiment of the present invention;
[0020] FIG. 5 is an illustration of example embodiments of a media
opening according to the present invention;
[0021] FIG. 6 is a perspective view of the sleeve illustrated in
FIG. 4 with phantom lines to show relative thickness;
[0022] FIG. 7 is a bottom plan view of the sleeve illustrated in
FIG. 4 with phantom lines to show relative thickness;
[0023] FIG. 8 is a cross-sectional side view of the sleeve
illustrated in FIG. 4, taken along section line 8-8 of FIG. 7;
[0024] FIG. 9 is a top plan view of a plunger according to one
embodiment of the present invention;
[0025] FIG. 10 is a cross-sectional side view of the plunger
illustrated in FIG. 9, taken along section line 10-10 of FIG.
9;
[0026] FIG. 11 is a cross-sectional side view of a media control
valve according to an aspect of the present invention;
[0027] FIG. 12 is an exploded, elevational view of the valve shown
in FIG. 11; and
[0028] FIG. 13 is a partial side view of one aspect of the present
invention.
DETAILED DESCRIPTION
[0029] The present invention is directed to a valve for controlling
the flow of a media to a fluid stream, referred to herein as a
media control valve. By media, it is meant any material or
materials that may be desired to be added to another material or
materials. While various solid, fine particulate, blasting media,
such as sand, metal shot, and the like, are used by way of example
herein, the media that may be supplied by the media control valve
of the present invention is not so limited, and may include a wide
variety of materials including liquids and gasses as well as solid
particles.
[0030] In one embodiment, the media control valve of the present
invention includes a valve body having a media inlet and a media
outlet. A housing is connected to the valve body. A plunger is
positioned within the valve body and is connected to a piston
positioned within the housing. A base is connected to the valve
body such that it communicates with the media outlet. The media
control valve of this embodiment may further include a sleeve
disposed between the valve body and the plunger. This sleeve may
contain a media opening. In some embodiments of the media control
valve of the present invention, the media opening has a first
portion proximate to the media outlet and a second portion distal
to the media outlet, the second portion being broader than the
first portion. In other embodiments of the invention, the piston
includes a contaminant isolation region. These and other specific
embodiments of the invention will now be described with reference
to the Figures.
[0031] FIG. 1 illustrates a typical system in which the media
control valve of the present invention may be employed. In FIG. 1,
a media control valve 10 is part of a blast system 150 used to
treat a surface by projecting a media 140 at the surface. Media 140
typically consists of solid particles, such as sand, shot, nut
shells, sodium bicarbonate, other abrasives, and the like depending
on the surface being treated and the materials(s) being removed
from the surface. Blast system 150 includes a fluid supply 100
which supplies a fluid stream through conduit 110. Typically, the
fluid employed is air, though any readily available, relatively
inert carrier fluid may be employed. Media 140 may be stored in a
media vessel 130 and supplied to the fluid stream within conduit
110 through actuation of media control valve 10. The fluid stream
and entrained media 140 then pass through conduit 110 to a nozzle
120 where they are directed at a surface to be treated.
[0032] Referring now to FIGS. 2 and 3, in one embodiment media
control valve 10 may include a valve body 20 having a media inlet
22 and a media outlet 24. A plunger 30 is positioned within valve
body 20 and a sleeve 32 is positioned between valve body 20 and
plunger 30. Sleeve 32 may include a media opening 34 that allows
media to pass from media inlet 22 to media outlet 24 when plunger
30 is not blocking such flow. In this embodiment, media control
valve 10 further includes a housing 40 that is connected to valve
body 20. A piston 42 is connected to plunger 30 and positioned
within housing 40. A base 60 is connected to valve body 20 such
that it communicates with media outlet 24.
[0033] Valve body 20 may be constructed in any manner and of any
materials that provide valve body 20 the desired configuration and
durability. For example, valve body 20 may be constructed with
media inlet 22. Media inlet 22 may be constructed in any manner
that allows it to receive media. For example, media inlet 22 may be
constructed to connect to a media vessel. When media inlet 22 is
constructed to connect with a media vessel, it may be constructed
to connect in any manner that provides a secure connection and
allows media to flow into valve body 20 from the media vessel. For
example, media inlet 22 may be threaded, or otherwise provided with
a fitting such that it may mate with a connector attached to the
media vessel.
[0034] Valve body 20 may also be constructed with media outlet 24.
Media outlet 24 may be constructed in any manner that allows media
to pass from valve body 20 into a fluid passage 62 within base 60.
For example, media outlet 24 may be an aperture of any size and
shape capable of delivering media in an adequate volumetric flow
through a conduit, and, most typically, to a blast nozzle. In
preferred embodiments, media outlet 24 may be shaped as a circular
hole.
[0035] Valve body 20 may also be constructed to house plunger 30.
Valve body 20 may include an open area having a shape corresponding
to plunger 30. Valve body 20 may also be constructed to allow
sleeve 32, seals 36 or seat 26 to reside within valve body 20. For
example, the opening in valve body 20 for receiving plunger 30 may
be large enough to also accommodate sleeve 32 or seals 36 between
plunger 30 and valve body 20. Similarly, valve body 20 may include
a portion shaped to accommodate seat 26, typically adjacent to
media outlet 24.
[0036] Valve body 20 may also be constructed with a mechanism for
allowing the media to pass out of the media vessel without passing
into the conduit. For example, valve body 20 may include a bypass
or cleanout 28. Cleanout 28 may be constructed in any manner which
allows the media to flow out of the media vessel without entering
the conduit. For example, cleanout 28 may include an opening in
valve body 20 communicating directly with media inlet 22. Typically
during operation of media control valve 10, cleanout 28 is closed.
Cleanout 28 may also include an opening onto which a cover may be
mated when it is desired to close cleanout 28.
[0037] Valve body 20 may be constructed of any material or
materials that have sufficient durability for valve body 20 and are
compatible with media and other materials which may come in contact
with valve body 20. For example, valve body 20 may be constructed
of various metals and metal alloys. Preferably, valve body 20 is
constructed of an aluminum alloy because of its relatively low
weight and cost and relatively high strength and abrasion
resistance. Preferably, the aluminum alloy has a hard-coat anodized
finish to improve its abrasion resistance. In one embodiment, valve
body 20 is constructed of 356 T6 aluminum alloy with a hard-coat
anodized finish.
[0038] Valve body 20 may be constructed by any method capable of
producing valve 20 from a desired material or materials of
construction. For example, where valve body 20 is constructed of
certain metals, valve body 20 may be cast, machined or both.
Preferably, valve body 20 is constructed by casting, and, more
preferably, investment casting, because casting is relatively
inexpensive and produces a relatively high quality product having
sufficient dimensional stability.
[0039] Referring now also to FIGS. 9 and 10, plunger 30 may be
constructed in any manner and using any materials resulting in
plunger 30 having the shape and durability to selectively prevent
flow of media through valve body 20. For example, plunger 30 may be
constructed in any shape that may mate with valve body 20, sleeve
32 and seals 36 to selectively prevent flow of media from media
inlet 22 to media outlet 24. In order to selectively prevent flow
of media, plunger 30 is typically constructed such that it may move
within valve body 20, selectively exposing a media opening 34 in
sleeve 32 and allowing the media to flow from media inlet 22 to
media outlet 24. Preferably, plunger 30 is cylindrical and of
uniform cross-section.
[0040] Plunger 30 may be constructed to mate with piston 42. For
example, plunger 30 may be threaded at one end, such that it may be
mated to piston 42 with a threaded nut 70. Alternatively, plunger
30 may thread directly into piston 42 or be connected with another
connector known to those of skill in the art.
[0041] Plunger 30 may be constructed of any material or materials
that are sufficiently durable and inert to selectively prevent the
passage of media through or past plunger 30 and to provide long
life of plunger 30. For example, plunger 30 may be constructed of
the same material or materials as valve body 20. However, as
plunger 30 may be subject to more wear than valve body 20, it is
preferred to construct plunger 30 of a more durable material than
valve body 20. For example, plunger 30 may be constructed of steel,
such as 304 stainless steel, with harder material, such as tungsten
carbide, on the outer, lower portion 31 of plunger 30. These
materials are selected due to their relatively high strength and
dimensional stability. Plunger 30 may be made by any conventional
method to produce the desired shape from the material or materials
of construction. For example, plunger 30 may be constructed by the
same method as valve body 20.
[0042] Referring now also to FIGS. 4-8, Sleeve 32 may be
constructed in any manner and of any materials to produce a desired
configuration to be contained within valve body 20 and to mate with
plunger 30. For example, sleeve 32 may be constructed as a
cylindrical annulus where plunger 30 is cylindrical and valve body
20 contains a cylindrical opening therein. Sleeve 32 may be
constructed with a media opening 34 to control the flow of media
from media inlet 22 to media outlet 24. Media opening 34 may be
constructed in any shape that controls the flow of media 140 from
media inlet 22 to media outlet 24 as desired when valve 10 is open.
For example, as illustrated in FIG. 5, media opening 34 may be
irregularly shaped, or, more conventional, with a circular,
elliptical, or other geometric shaped opening; alternatively it may
only include a narrow opening. Preferably, as illustrated in FIGS.
4 and 6, media opening 34 includes a first portion 200 proximate to
media outlet 24 and a second portion 202 distal to media outlet 24,
second portion 202 being broader than first portion 200. This
embodiment of media opening 34 facilitates metering particulate
media when media valve 10 is in a partially open position.
[0043] In some embodiments, the flow control function of media
opening 34 in sleeve 32 may be constructed directly into valve body
20. For example, valve body 20 may be constructed in a manner which
is equivalent to sleeve 32 being fused to valve body 20. However,
it is preferable to have a separate sleeve 32 because this allows
relatively straightforward modification of media opening 34, and,
thus, the flow properties of media control valve 10, and because
sleeve 32 may be subject to wear and may need periodic
replacement.
[0044] Sleeve 32 may be formed out of any material that may be
shaped as desired and provides sufficient durability. For example,
sleeve 32 may be formed of a material that may maintain the shape
of media opening 34 despite the passage of media 140 through media
opening 34 over time. In some embodiments, sleeve 32 may be
constructed of a metal, metal alloy or polymer. Preferably, sleeve
32, like plunger 30, is constructed of steel with tungsten carbide
on the surfaces subject to the most wear, such as the inner, lower
portion 35 of sleeve 32. Again, these materials are selected due to
their abrasion resistance and dimensional stability. However, it
should be understood that the preferred material of construction
for sleeve 32 may vary with the media used and, in other
embodiments, other materials may be preferred. For example, in some
embodiments, it is preferred to form sleeve 32 from urethane
because of its cost, serviceability and resistance to jamming with
certain media, such as steel shot. Sleeve 32 may be constructed by
any method that produces sleeve 32 having the desired shape and
durability out of the material or materials of construction. For
example, sleeve 32 may be constructed by sintering, casting or
molding and polymerization of a prepolymer.
[0045] One or more seals 36 may be positioned between plunger 30
and valve body 20 to prevent media, fluid from the conduit or other
contaminants from passing between valve body 20 and housing 40. In
a preferred embodiment, three seals 36 are positioned between
plunger 30 and valve body 20 to prevent contamination. Typically,
the likelihood of contamination is much greater from valve body 20
to housing 40 than the reverse. Accordingly, seals 36 are typically
oriented to face valve body 20. In some instances, such as where
the pressure within housing 40 may exceed the pressure within valve
body 20, one or more of seals 36 may be oriented to face housing
40. In such instances, it is preferred that seals 36 closest to
housing 40 be faced toward housing 40. In one embodiment, several
seals 36 are formed as a unitary structure. For example, three
seals may be formed as a single solid piece of material.
[0046] Seals 36 may be formed out of any material that will provide
an adequate seal with sufficient durability. For example, seals 36
may be formed of a resilient, pliable material, such as some
polymers. The material may also be abrasion resistant and have a
low coefficient of friction. In some instances, seals 36 may be
constructed of an elastomer. Preferably, seals 36 are constructed
of molythane because it is self-lubricating or urethane because of
its abrasion resistance. Seals 36 may be constructed by any method
that produces seals 36 having the desired seal and durability out
of the material or materials of construction. For example, seals 36
may be constructed by molding and polymerization of a
prepolymer.
[0047] Seat 26 may be constructed of any material or materials and
in any manner that produces a solid connection with plunger 30 when
media control valve 10 is in a closed position. For example, seat
26 may be constructed to fit snugly with plunger 30. In embodiments
where plunger 30 is cylindrical, seat 26 may be a circular annulus.
Seat 26 may be constructed of the same materials and using the same
methods as seals 36. Seat 26 may also be constructed of less
resilient materials than would typically be used for seals 36 and
may even be formed of the same material as valve body 20.
[0048] Housing 40 may be constructed in any manner and of any
material or materials that produce housing 40 that may be connected
to valve body 20, house piston 42 and have sufficient durability.
For example, housing 40 may be constructed to function as a
cylinder for piston 42. Preferably, the inside of housing 40 is a
uniform circular cylinder, however, this is not required as long as
the inside of housing 40 connects with piston 42 to provide a seal.
Housing 40 may be constructed such that piston 42 may travel within
housing 40. Preferably piston 42 has sufficient range of motion to
allow plunger 30 to move from a fully open position in which
plunger 30 does not obstruct media opening 34 to a fully closed
position in which plunger 30 rests against valve seat 26,
completely obstructing flow through media opening 34. Piston 42 may
effectively divide housing 40 into a drive chamber 44 and an
exhaust chamber 46. Where housing 40 has a drive chamber 44,
housing 40 may be constructed with a drive inlet 48 to drive
chamber 44, allowing pressure to be applied to piston 42 to open
media control valve 10.
[0049] Housing 40 may also include one or more vents 50 in exhaust
chamber 46, allowing fluid to flow into and out of exhaust chamber
46 as the volume within exhaust chamber 46 varies with the motion
of piston 42. Vents 50 may include filters 52 to prevent
contaminants from entering housing 40 while still allowing vents 50
to perform their exhaust function. Preferably, filters 52 in vents
50 are capable of filtering particles larger than about 20 microns
as this filters most particles, but does not restrict the flow of
fluid through vents 50 enough to significantly affect performance
of media control valve 10. Furthermore, particles less than about
20 microns may be able to fit between housing 40 and piston 42 and
are less likely to damage piston 42 or cause piston seal 58 to
fail. A suitable filter 52 may be constructed by sintering an
appropriate material, such as a metal of metal alloy. Preferably
the filter is constructed of sintered brass.
[0050] Housing 40 may be constructed to provide access to the
inside of housing 40. For example, housing 40 may include a cap 66,
which may be removed to provide access to the inside of housing 40.
Cap 66 may be constructed in any manner that allows it to connect
securely with housing 40 yet allows access to the inside of housing
40. For example, cap 66 may be constructed to cover the open top of
housing 40, and may include structure allowing it to be connected
to housing 40. In one embodiment, cap 66 and housing 40 may include
matching holes, through which bolts 68 may be inserted to secure
cap 66 to housing 40. Preferably, in order to insure a secure
connection, four evenly spaced bolt holes 64 and bolts 68 are used
to secure cap 66 to housing 40. Cap 66 may be constructed of the
same materials and by the same method as housing 40.
[0051] Housing 40 may also be constructed to include structure to
allow the adjustment of the operation of media valve 10. For
example, housing 40 may enclose a spring 56 and attendant structure
to adjust the tension on spring 56 and, thus, the operation of
media control valve 10. Alternatively, housing 40 may include an
air shock (not shown) and attendant structure. In one embodiment,
spring 56 rests between piston 42 and cap 66, biasing piston 42 and
plunger 30 toward media outlet 24 and thus biasing media control
valve 10 into a closed position. The tension on spring 56 may be
used to control how difficult it is to move piston 42, and thus,
the amount of pressure required to actuate media control valve 10
or the degree of actuation for a given pressure. Structure to
adjust the tension on spring 56 may include a spring retainer 80
that mates with housing 40. Where spring retainer 80 is used to
allow the tension on spring 56 to be adjusted, a device for
facilitating the adjustment of spring retainer 80, such as a knob
82, crank or other handle, may be used. An O-ring 84, or like seal,
may be positioned between spring retainer 80 and housing 40, to
prevent the ingress of contaminants into housing 40. Media control
valve 10 may include a metering indicator. For example, spring
retainer 80 may include marking corresponding to the degree to
which media control valve 10 is open.
[0052] Housing 40 may be constructed of any material or materials
that may be shaped in the desired configuration and has sufficient
durability to provide long life. For example, housing 40 may be
constructed of the same materials as valve body 20. Similarly,
housing 40 may be constructed using the methods discussed with
respect to valve body 20.
[0053] Piston 42 may be constructed in any manner and using any
materials that allow it to fit snugly within housing 40 and to
connect with plunger 30 such that plunger 30 is moved with the
motion of piston 42. For example, piston 42 may relatively flat and
shaped to match the cross-section of housing 40. Typically, piston
42 will be circular to match the circular cross-section of
cylindrical housing 40. Piston 42 may be constructed with structure
to connect it to plunger 30. For example, where plunger 30 includes
a threaded region, piston 42 may have a hole therein through which
a portion of plunger 30 is inserted, and nut 70 threaded onto, to
attach piston 42 to plunger 30.
[0054] Piston 42 may be constructed with structure to insure that
fluid, media, contaminants and other materials are prevented from
passing between drive chamber 44 and exhaust chamber 46 of housing
40. For example, piston 42 may be constructed with one or more
retainers adapted to maintain a piston seal 58 in place around
piston 42.
[0055] Piston 42 may be constructed to reduce the adverse effect of
media and other contaminants that find their way into drive chamber
44. For example, piston 42 may include a contaminant isolation
region 48 where contaminants are collected and isolated from more
sensitive areas of media control valve 40, such as the walls of
housing 40 and piston seal 58. In one embodiment, contaminant
isolation region 48 includes a recess in piston 42. In this
embodiment, piston 42 may have an overall dish shape, allowing
contaminants to settle into the dish.
[0056] Piston 42 may be constructed of any material or materials
that provide sufficient rigidity and durability. For example,
piston 42 may be constructed of a metal, metal alloy or polymer.
Preferably, piston 42 is constructed of aluminum because of its
relatively high strength and relatively low cost and weight. More
preferably, piston 42 is constructed of 356 T6 aluminum. Piston 42
may be hard-coat anodized. Piston 42 may be constructed by any
method that produces piston 42 from the desired material or
materials of construction, such as casting, machining or
molding.
[0057] In some embodiments, structure to prevent piston 42 from
impacting against housing 40 or cap 66 may be included in media
control valve 10. For example, structure may be positioned within
housing 40 to absorb the impact of piston 42 striking housing 40 or
cap 66. In one embodiment, this structure may comprise a bumper,
such as bump ring 86, capable of absorbing the impact of piston 42
striking it. Bump ring 86 may be constructed in any manner and of
any material or materials that allow it to intercept piston 42 and
to dissipate some of its impact energy. For example, bump ring 86
may be constructed as an elastomeric ring and made by a method
suitable to the material. Preferably, bump ring 86 is constructed
from neoprene because of its impact absorbing ability.
[0058] While a conventional piston is described by way of example
herein, it should be understood that piston 42 may also be
constructed as a diaphragm. Where piston 42 is constructed as a
diaphragm, it may be constructed such that it is connected at its
edges to housing 40, but is free to move in a central portion
connected to plunger 30. For example, piston 42 may be constructed
of a flexible material, which may be an elastomer. Such material
may be selected based on its degree of flexibility and its ability
to withstand repeated flexing over an extended period of operation
of media control valve 10.
[0059] In some instances, media control valve 10 may be subject to
significant vibration, for example, due to a mechanical agitator
operated to improve media flow. Vibration is undesirable because it
may, for example, result in a change in metering position.
Accordingly, it may be desired to add structure to media control
valve 10 that dampens vibration. For example, a structure capable
of absorbing vibrational energy or adding friction to prevent parts
from vibrating apart may be included in media control valve 10. In
one embodiment, a vibration disc 88 is positioned between spring 56
and spring retainer 80 to create friction and prevent slipping of
spring retainer 80, potentially resulting in a loss of metering
position. Vibration disc 88 may be constructed in any manner and of
any material or materials that allow it create friction between two
parts. However, vibration disc 88 should not create so much
friction that it prevents adjustment or detachment of the parts.
For example, vibration disc 88 may be circular, polygonal or of any
other shape and may be formed of any material having a relatively
high coefficient of friction. Typically, vibration disc 88 is
formed of a polymeric material. Preferably, vibration disc 88 is
constructed of polyurethane because it may create friction without
preventing adjustment.
[0060] Base 60 may be constructed in any manner and of any
materials that allow communication between media outlet 24 and
fluid passage 62. For example, base 60 may be adapted to be
attached to valve body 20 and conduit 110, such that fluid passage
62 is in communication with both media outlet 24 and conduit 110.
Typically, an opening in base 60 is placed in communication with
media outlet 24, allowing media to pass into fluid passage 62.
Where base 60 is in communication with media outlet 24, it is
preferred that the opening between base 60 and media outlet 24 not
impede the flow of media into fluid passage 62 or the ability of
plunger 30 to close media control valve 10. For example, the
opening between media outlet 24 and gas passage 62 may be larger
than media opening 34 in sleeve 32, ensuring that it is not the
flow-limiting restriction and allowing media to disperse, making it
easier for plunger 30 to move the media aside as it closes.
[0061] Base 60 may be constructed with structure allowing it to be
connected to valve body 20. The structure allowing base 60 to be
attached to valve body 20 may be integrally formed with base 60,
allowing base 60 to be unitary structure. This embodiment is in
contrast to typical media control valve bases wherein the base
consists of several pieces, such as a separate fluid passage 62 and
attachment structure for attaching fluid passage 62 to valve body
20.
[0062] In one embodiment, base 60 may include bolt holes 64 through
which bolts 68 may be passed to connect base 60 to valve body 20.
Preferably, bolt holes 64 extend not only through base 60 but also
through valve body 20 and into housing 40. Where bolt holes 64
extend through base 60 and valve body 20 into housing 40, removing
bolts 68 allows media control valve 10 to be quickly disassembled
for inspection, modification or maintenance. For example, bolts 68
may be removed to allow access to and replacement of sleeve 32,
such that sleeve 32 may be replaced with an alternate sleeve 32
having a different media opening 34. As another example, bolts 68
may be removed to provide access to seals 36 for routine
maintenance and repair. Preferably, base 60, valve body 20 and
housing 40 each include four corresponding bolt holes evenly
distributed about such structures to provide a secure connection
therebetween. Housing 40 and valve body 20 may include further
mating structure that facilitates the attachment of housing 40 and
body 20. For example, one of housing 40 and valve body 20 may
include a grove 38 or protrusion 54 that mates with a corresponding
groove 38 or protrusion 54 in the other one of housing 40 and valve
body 20.
[0063] Base 60 may be constructed of any material that may be
shaped in the desired configuration and has sufficient durability
to provide long life. For example, base 40 may be constructed of
various metals or metal alloys. In a preferred embodiment, base 60
is constructed of carbon steel, such as 4140 carbon steel, because
of its strength, cost, and ability to be hardened and cast. Where
base 60 is constructed of carbon steel, it may be heat treated, for
example, to approximately 55 Rockwell C, and may be phosphate
coated to inhibit rusting. Base 40 may be constructed using the
methods discussed with respect to valve body 20.
[0064] In some embodiments, fluid passage 62 may be subject to
mechanical or chemical damage. Accordingly, structure may be added
to fluid passage 62 to resist such damage. For example, a flow
sleeve (not shown) may be positioned within fluid passage 62. The
flow sleeve may be constructed of any material that is sufficiently
chemically and/or mechanically resistant. For example, the flow
sleeve may be constructed of polyurethane by conventional
techniques.
[0065] An alternate embodiment of a media control valve 10 of the
present invention is illustrated in FIGS. 11-12. This embodiment
serves as an example of another of the variety of valve structures
within the scope of the present invention and illustrates other
features that may be incorporated into the media control valves of
the present invention.
[0066] One common wear point in conventional valves is seat 26.
Traditional plungers have sharp edges where the side of the plunger
meets the end of the plunger (typically at right angles). It has
been discovered that this sharp edge leads to the degradation of
the valve seat. Accordingly, one embodiment of media control valve
10 provides a gentle seal. By gentle seal, it is meant a seal in
which there are no sharp edges forced against the seat when the
valve is closed. Such an embodiment is illustrated in FIGS. 11 and
12.
[0067] In one embodiment, a gentle seal may be provided by any
structure on plunger 30 or seat 26 that does not provide a hard or
sharp edge abutting seat 26. For example, the end of plunger 30 may
be rounded or beveled, or may include a rounded or beveled
structure attached thereto. In one embodiment, the entire end of
plunger 30 is beveled or rounded. In another embodiment, just the
edges of plunger 30 are rounded or beveled. As illustrated in FIG.
13, where plunger 30 is beveled, the bevel angle 100 may be less
than about 60 degrees with respect to a plane 98 defined by the end
of plunger 30. In other embodiments, bevel angle 100 may be less
than about 45 degrees, less than about 30 degrees, or less than
about 15 degrees.
[0068] Where a gentle seal is provided, seat 26 may be as described
previously and is preferably a flexible material, such as
polyurethane, which may improve the seal. Seat 26 may also be
constructed to facilitate formation of a gentle seal. For example,
seat 26 may be shaped to mate with plunger 30, having a curved or
beveled edge at its opening, or the like.
[0069] Conventional media control valves, and even the valve of the
embodiment of the invention illustrated in FIGS. 2 and 3, include a
media flow path that causes media to change direction and thus
impact against it as it passes through the path. By media flow
path, it is meant a path between media inlet 22 and media outlet 24
through which media passes when valve 10 is open. It has now been
recognized that because of the impact between the media and the
media flow path, the media flow path may be degraded. Furthermore,
the flow of media may be slowed and impeded by the contact.
Accordingly, in one embodiment, the present invention is directed
to a media control valve 10 having a flow path 92 designed to
reduce impact with the media. For example, as illustrated in FIG.
11, flow path 92 may have a substantially linear axis 96. Media
flow path 92 having substantially linear axis 96 may be free of
bends, crooks, and the like, such that media may flow directly from
media vessel 130 into fluid path 62 with little or no contact with
media flow path 92. Reduction of contact between media flow path 92
and the media may be facilitated by orienting media flow path 92
substantially perpendicularly with respect to the surface upon
which the media control system rests. However, such and arrangement
is not required, particularly where the flow of media is primarily
due to a pressure differential rather than to gravitational forces.
Media flow path 92 may be oriented substantially perpendicularly
with respect to fluid path 62, which, in most embodiments, will be
an air flow path. It should be appreciated that some contact
between media flow path 92 and the media is largely unavoidable.
For example, contact may occur because of scattering of the media
or narrowing of media flow path 92. Nonetheless, to the extent that
impact is reduced by straightening of media flow path 92, such an
arrangement is within the scope of the present invention.
[0070] To facilitate alignment of sleeve 32 such that media opening
34 is properly oriented, structure may be included on sleeve 32
and/or valve body 20. For example, a mating structure such as a
ridge and groove, pin and hole, or the like, may be used to
facilitate proper alignment. In the embodiment illustrated in FIGS.
11 and 12, a separate sleeve pin 90 is designed to mate with
corresponding holes in valve body 20 and sleeve 32.
[0071] The illustrative embodiment of FIGS. 11 and 12 demonstrates
that media control valve 10 according to the present invention may
be constructed relatively simply and, where desired, may be of
small size. Such an embodiment may be preferred, for example, in
applications where a small, simple valve may be desired to decrease
cost or to increase portability. To make media control valve 10
smaller, simpler and less expensive, it may be constructed as an
on-off valve, meaning that it has only fully open and fully closed
positions. In such an on-off valve, flow control may be
accomplished by changing the size of media opening 34 or the
pressure differential across the valve. In addition to the
improvements already noted, this embodiment includes a plunger 30
capable of also functioning as a piston in housing 40, lowering
cost and improving serviceability. This embodiment, as any
embodiment of the present invention, may be constructed of the
materials and in the manner previously described herein.
[0072] It should be appreciated that the features of the embodiment
of the invention illustrated in FIGS. 11 and 12 and the embodiment
illustrated in FIGS. 2 and 3 are interchangeable and may be
combined or interchanged with other features of conventional media
control valves. For example, the use of a media opening 34 having a
narrower and a broader portion may be accommodated in the
embodiment illustrated in FIGS. 11 and 12. Similarly, the use of a
media flow path 92 having a substantially linear axis 96 may be
desirable in the embodiment illustrated in FIGS. 2 and 3.
[0073] Having thus described certain embodiments of the present
invention, various alterations, modifications and improvements will
be apparent to those of ordinary skill in the art. Such
alterations, variations and improvements are intended to be within
the spirit and scope of the present invention. Accordingly, the
foregoing description is by way of example and is not intended to
be limiting. The present invention is limited only as defined in
the following claims and the equivalents thereto.
* * * * *