U.S. patent application number 16/184138 was filed with the patent office on 2019-03-14 for poppet valve assembly, system, and apparatus for use in high speed compressor applications.
This patent application is currently assigned to Compressor Engineering Corporation. The applicant listed for this patent is Compressor Engineering Corporation. Invention is credited to Catherine Jones, Gene M. Thompson.
Application Number | 20190078564 16/184138 |
Document ID | / |
Family ID | 42098043 |
Filed Date | 2019-03-14 |
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United States Patent
Application |
20190078564 |
Kind Code |
A1 |
Thompson; Gene M. ; et
al. |
March 14, 2019 |
Poppet Valve Assembly, System, and Apparatus for Use in High Speed
Compressor Applications
Abstract
A poppet valve assembly for a high-speed compressor, the poppet
valve assembly including a cage that includes a plurality of
counter bores disposed therein. The poppet valve assembly further
includes a plurality of poppets, each poppet having a stem and a
head. The head of each poppet has a maximum diameter that is less
than approximately 0.75 inches. The stem of the poppet is disposed
in each of said counter bores. The poppet valve assembly also
includes a seat plate overlying said cage, said seat plate
including a plurality of through bores axially aligned with the
counter bores of the cage. Each through bore is sized to have a
smaller diameter than the maximum diameter of the head. A lift
spacer is disposed in each of the counter bores.
Inventors: |
Thompson; Gene M.; (Cypress,
TX) ; Jones; Catherine; (Missouri City, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Compressor Engineering Corporation |
Houston |
TX |
US |
|
|
Assignee: |
Compressor Engineering
Corporation
Houston
TX
|
Family ID: |
42098043 |
Appl. No.: |
16/184138 |
Filed: |
November 8, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12572071 |
Oct 1, 2009 |
|
|
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16184138 |
|
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61194882 |
Oct 1, 2008 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 39/1013
20130101 |
International
Class: |
F04B 39/10 20060101
F04B039/10 |
Claims
1. A compressor system, the compressor system comprising: a
high-speed gas compressor operable at speeds of at least 600 rpm,
said high-speed compressor further comprising a high-speed poppet
valve assembly, wherein the high-speed poppet valve assembly
comprises: a high-speed cage plate, said high-speed cage plate
including a plurality of counter bores disposed therein wherein
each counter bore has an open end and a bottom in the high-speed
cage plate; a plurality of high-speed poppet elements, each
high-speed poppet element including a guide stem having an outer
stem diameter and a mushroom shaped head with a smooth continuous
sealing surface, wherein the head has a maximum diameter that is
both less than approximately 0.9 inches and larger than the outer
stem diameter, and wherein the guide-stem is disposed proximate to
a cage plate wall of one of said counter bores in a guide
relationship with said counter bore; a coil spring disposed in a
hollow portion of the guide-stem having bias characteristics
suitable for a high-speed poppet-head operation; a high-speed seat
plate overlying said high-speed cage, said high-speed seat plate
including a plurality of through bores axially aligned with the
plurality of counter bores of the high-speed cage, wherein each of
the plurality of through bores is sized to have a smaller diameter
than the maximum diameter of the head; and a lift spacer disposed
in at least one of said plurality of counter bores wherein said
lift spacer limits axial movement and controls lift of said guide
stem to an amount less than the length of said cage plate and an
amount suitable for high-speed poppet-head operation.
2. The system of claim 1, wherein said lift spacer includes an
aperture therethrough.
3. The system of claim 1, wherein the maximum diameter of the head
is less than approximately 0.75 inches.
4. The system of claim 1, wherein a first lift spacer, which
controls lift of a first poppet-head and is disposed in a first of
said plurality of counter bores, has different dimensions than a
second lift spacer, which controls lift of a second poppet-head and
is disposed in a second of said plurality counter bores.
5. The system of claim 1, wherein said high-speed compressor is
operable at speeds of at least 1000 rpms.
6. A compressor system, the compressor system comprising: a
high-speed gas compressor operable at speeds of between about 600
and about 1500 cycles per minute, said high-speed compressor
further comprising a high-speed poppet valve assembly, wherein the
high-speed poppet valve assembly comprises: a high speed cage
plate, said cage plate including a plurality of counter bores
disposed therein; a plurality of high-speed poppet elements, each
high-speed poppet element including a guide stem having an outer
stem diameter and a mushroom shaped head with a smooth continuous
sealing surface, each high-speed poppet element composed of a high
performance engineering thermoplastic, wherein the head has a
diameter between approximately one half and three quarters of an
inch, the head diameter being larger than the outer stem diameter,
and wherein the guide-stem is disposed proximate to a cage plate
wall of one of said plurality of counter bores in a guide
relationship with said counter bore; a coil spring disposed in a
hollow portion of the guide-stem having bias characteristics
suitable for a high-speed poppet-head operation; a seat plate
overlying said cage, said seat plate having a plurality of through
bores axially aligned with the said plurality of counter bores of
the cage, said seat plate being composed of steel, wherein each
through bore is sized to have a smaller diameter than the diameter
of the poppet head; and a lift spacer disposed in each of the said
plurality of counter bores.
7. The poppet valve assembly of claim 6, wherein each said lift
spacer includes an aperture therethrough.
8. The poppet valve assembly of claim 6, wherein each guide stem is
cylindrical.
9. The poppet valve assembly of claim 6, wherein each poppet has a
mushroom shaped cross section.
10. The poppet valve assembly of claim 6, further comprising at
least one alignment pin, at least one through hole in the seat, and
at least one through hole in the cage, wherein the alignment pin is
located within both the at least one through hole in the seat and
the at least one through hole in the cage.
11. The poppet valve assembly of claim 6, wherein each cage plate
counter bore has a chamfer.
12. The poppet valve assembly of claim 11, wherein each cage plate
counter bore chamfer is approximately 45 degrees.
13. The poppet valve assembly of claim 6, wherein the cage is
cylindrical.
14. The poppet valve assembly of claim 6, wherein each through bore
on the seat plate is chamfered.
15. The poppet valve assembly of claim 14, wherein each seat plate
chamfer is approximately 45 degrees.
16. The poppet valve assembly of claim 6, wherein the plurality of
poppets and corresponding through bores are arranged in at least
two arrays of two different diameters, centered about the center
axis of the cage.
17. The poppet valve assembly of claim 6, wherein the diameter of
the cage plate counter bores is less than the diameter of the
poppet heads.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Nonprovisional
patent application Ser. No. 12/572,071, filed Oct. 1, 2009, which
claims priority to U.S. provisional patent application No.
61/194,882, filed on Oct. 1, 2008 in the U.S. Intellectual Property
Office, the disclosure of which is incorporated herein by reference
in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to high-speed compressors, and
more particularly, to control of gas flow in high-speed compressors
utilizing a poppet valve assembly.
2. Description of the Prior Art
[0003] Gas valve assemblies for conventional compressors, namely
those operating at between approximately 200 rpm and approximately
600 rpm, often include poppets that have a head diameter ranging
from approximately 1 inch to approximately 1 and 1/8 inches.
Typically, such systems utilize approximately two to four poppets
with heads in this size range to control fluid flow within these
compressors. The size of such conventional poppets in the valve
assemblies of these conventional compressors does not allow for
precise control of fluid flow, because a limited number of such
conventional poppets may be included within the conventional valve
assembly. However, for such conventional operating speeds, these
conventional flow control systems have been adequate. There is a
need, however, for more precise gas control in certain high-speed
compressor applications, particularly those operating in the
600-1500 range or higher.
SUMMARY
[0004] The present disclosure relates generally to a valve assembly
that includes miniature poppets which may be utilized with
high-speed compressor applications. One of the broader forms of
invention may provide a poppet valve assembly, the poppet valve
assembly including a cage that includes a plurality of counter
bores disposed therein. The poppet valve assembly further includes
a plurality of poppets, each poppet having a stem and a head. The
head of each poppet has a maximum diameter that is less than
approximately one inch. The stem of the poppet is disposed in a
corresponding one of the said plurality of counter bores. The
poppet valve assembly also includes a seat plate overlying said
cage, said seat plate including a plurality of through bores
axially aligned with the plurality of counter bores of the cage,
wherein each of the plurality of through bores is sized to have a
smaller diameter than the maximum diameter of the head. A lift
spacer is disposed in each of the counter bores.
[0005] According to another of the broader forms of the invention
may provide an apparatus that includes a poppet valve assembly, the
poppet valve assembly including a cage that includes a plurality of
counter bores disposed therein. The poppet valve assembly further
includes a plurality of poppets, each poppet having a stem and a
head. The head of each poppet has a maximum diameter that is less
than approximately one inch. The stem of the poppet is disposed in
a corresponding one of the said plurality of counter bores. The
poppet valve assembly also includes a seat plate overlying said
cage, said seat plate including a plurality of through bores
axially aligned with the plurality of counter bores of the cage.
Each of the plurality of through bores is sized to have a smaller
diameter than the maximum diameter of the head. A lift spacer is
disposed in each of the counter bores.
[0006] According to another of the broader forms of the invention
may provide a system that includes a compressor that includes a
poppet valve assembly, the poppet valve assembly including a cage
that includes a plurality of counter bores disposed therein. The
poppet valve assembly further includes a plurality of poppets, each
poppet having a stem and a head. The head of each poppet has a
maximum diameter that is less than approximately one inch. The stem
of the poppet is disposed in a corresponding one of the said
plurality of counter bores. The poppet valve assembly also includes
a seat plate overlying said cage, said seat plate including a
plurality of through bores axially aligned with the plurality of
counter bores of the cage. Each of the plurality of through bores
is sized to have a smaller diameter than the maximum diameter of
the head. A lift spacer is disposed in each of the counter
bores.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Aspects of the present disclosure are best understood from
the following detailed description when read with the accompanying
figures. It is emphasized that, in accordance with the standard
practice in the industry, various features are not drawn to scale.
In fact, the dimensions of the various features may be arbitrarily
increased or reduced for clarity of discussion.
[0008] FIG. 1 illustrates a top view of an exemplary poppet valve
according to one or more aspects of the present disclosure.
[0009] FIG. 2 illustrates a partial cross-sectional view of an
exemplary poppet valve according to one or more aspects of the
present disclosure.
DETAILED DESCRIPTION
[0010] The present disclosure relates generally to a valve assembly
that includes miniature poppets which may be utilized with
high-speed compressor applications. It is understood, however, that
specific embodiments are provided as examples to teach the broader
inventive concept, and one of ordinary skill in the art can easily
apply the teaching of the present disclosure to other methods or
apparatus. Also, it is understood that the apparatus discussed in
the present disclosure includes some conventional structures. Since
these structures are well known in the art, they will only be
discussed in a general level of detail. Furthermore, reference
numbers are repeated throughout the drawings for sake of
convenience and example, and such repetition does not indicate any
required combination of features or steps throughout the
drawings.
[0011] Referring to FIG. 1, a top view of a poppet valve assembly
102 in accordance with an embodiment of the present disclosure is
shown. The poppet valve assembly 102 includes a cage, stop plate or
guard 104 in which a plurality of counter bores 108 (shown as
108a-i in FIG. 1) are disposed in one preferred embodiment, cage
104 may be substantially circular in shape although the shape of
cage 104 is not a limitation of the invention and those skilled in
the art will understand that cage 104 can be of any desirable
shape.
[0012] A plurality of miniature poppets 112 (shown as 112a-i in
FIG. 1) with a maximum outer diameter of one inch and preferably
0.9 inches or smaller are disposed in the plurality of counter
bores 108a-i. Each of the plurality of poppets 112 seats in a
respective one of the plurality of counter bores 108 provided in
the cage 104. In the embodiment of FIG. 2, the poppet valve
assembly 102 includes nine poppets 112a-i that are arranged in the
cage 104 around two diameters 116 and 120. A first smaller diameter
116 has three poppets 112a-c that are substantially equally spaced
around the smaller diameter 116, and a second larger diameter 120
has six poppets 112d-i that are substantially equally spaced around
the larger diameter 120. In other embodiments, the poppet valve
assembly 102 may include a plurality of poppets 112 positioned
according to any conventional arrangement. In any event, it is
desirable that by utilizing unconventionally small diameter
poppets, a greater surface area of cage 104 can be covered by
poppets 112, thereby permitting the same volume of gas to pass
therethrough, but in a more controllable manner.
[0013] The poppet 112 is fabricated from a high performance
engineering thermoplastic. However, in other embodiments, the
poppet valve assembly 102 may be fabricated from other materials,
including without limitation, hardened steel, other metals or metal
alloys.
[0014] Referring now to FIG. 2, a partial cross-sectional view of a
portion of the poppet valve assembly 102 that includes a poppet 112
is shown. The plurality of poppets in assembly 102 are
substantially similar to one another. Of course, those skilled in
the art will appreciate that in other embodiments, the poppets 112
may vary as described with respect to embodiments of the present
disclosure. In any event, poppet 112 includes a stem 204 and a head
208, and is substantially mushroom-shaped, because the head 208 is
larger than the stem 204.
[0015] In one embodiment, the head 208 has a maximum diameter 209
that is approximately 0.71 inches, and the stem 204 has a maximum
diameter 210 that is approximately 0.446 inches. In another
embodiment, the maximum diameter 209 of the head 208 may be less
than approximately 0.75 inches, and the maximum diameter 210 of the
stem 204 may be less than approximately 0.446 inches. In yet
another embodiment, the maximum diameter 209 of the head 208 may be
less than approximately 1 inch. The head 208 includes a sealing
surface 212 that has a diameter that is larger than the maximum
diameter 210 of the stem 204.
[0016] The stem 204 of poppet 112 is disposed in a counter bore
108. Preferably, the stem 204 is hollow, and is adapted to house or
guide a spring 216. The spring 216 is disposed in the stem 204 so
as to seat in the counter bore 108. A lift spacer 220, having an
aperture 224 therethrough, is positioned at the bottom of counter
bore 108. The spring 216 is disposed to urge the poppet 112 toward
a seat plate 228 overlying the cage 104, and thereby place the
poppet 112 in a closed position. Like poppet 112, lift spacer 220
may be fabricated from a high performance engineering
thermoplastic. However, in other embodiments, lift spacer 220 may
be fabricated from other materials, including without limitation,
hardened steel, other metals or metal alloys.
[0017] The seat plate 228 includes a plurality of through bores
232, each axially aligned with a counter bore 108. The through bore
232 is sized to have a smaller diameter than the maximum diameter
209 of the head 208. An edge 233 of the through bore 232 that
interfaces with the sealing surface 212 is disposed to form a seat
for receipt of head 208, preferably forming a metal to metal seal
between the seat plate 228 and the head 208. In one preferred
embodiment, edge 233 has a 45 degree chamfer to enhance sealing
between the head 208 and the seat plate 228. However, in other
embodiments, other shaped edges may be used to create a seal or
seat. For example, the angle of edge 233 may be selected to
correspond with the angle or shape of the sealing surface 212 that
interfaces with the seat plate 228.
[0018] Each through bore 232 represents an independent, separately
controllable orifice through which fluid may flow. By decreasing
the size of the orifices, but increasing their number in poppet
valve assembly 102, more precise control of fluid flow, namely gas
flow into a high speed compressor, can be achieved.
[0019] Preferably, the seat plate 228 is a replaceable seat plate,
and includes a hardened steel plate that covers the poppet valve
assembly 102. In other embodiments, the seat plate 228 may include
a plate that is manufactured using other materials. Most desirably,
seat plate 228 is replaceable in the event of debris damage or
excessive wear thereto. Conventional poppet valves do not include
replaceable seat plates, and therefore the entire valve seat-body
of such conventional poppet valve assemblies must be replaced.
Thus, in this regard, seat plate 228 is readily detachable from
cage 104. Although any conventional fastener may be utilized, in
the embodiment of FIG. 2, seat plate 228 is attached to cage 104
with threaded fasteners 235.
[0020] The poppet valve assembly 102 may also includes an alignment
pin 236 that is positioned between the seat plate 228 and the cage
104. The alignment pin 236 facilitates proper alignment of
components of the poppet valve assembly 102 during manufacture and
removal and replacement of seat plate 228. Again, because
conventional assemblies were not replaceable, such alignment pins
236 were not necessary.
[0021] The cage 104 and the seat plate 228, when joined together,
form a flow channel 237 that extends from the through bore 232
through the poppet valve assembly 102. The cage 104 and lift spacer
220 provide a versatile poppet valve assembly 102 that enables
multiple flow area configurations, simplified assembly and
manufacturing, and enhanced flow characteristics.
[0022] The flow area of the poppet valve assembly 102, and
specifically, the flow through each through bore 232, can be
readily adjusted by adjusting the lift spacer 220 underlying the
poppet 112. The amount of axial movement of the poppet 112 is
controlled by the lift spacer 220, which in turn controls the
amount of fluid flow through the poppet valve assembly 102. The
through bore 232, and subsequently the open cross-sectional area
between the through bore 232 and head 208, is generally controlled
by the lift spacer 220 and the sizing of the poppet itself, as well
as the reduced opening in the seating surface.
[0023] As specified above, the poppets 112 are smaller than
conventional poppets. For example, a conventional poppet may have a
head 208 that has a diameter that ranges from approximately 1 inch
to approximately 1 and 1/8 inches. In contrast, the head 208 of
each of the poppets 112 has a maximum diameter 209 that is
preferably approximately 0.71 inches, although this dimension may
range in one preferred embodiment from approximately 0.5 inches to
0.9 inches. In another preferred embodiment, valve 102 includes at
least 6 poppets 112, while in another preferred embodiment, valve
102 includes at least 9 poppets 112. Of course, the number of
poppets 112 depends in part on the size of cage 104. However, it
has been found that approximately 50% to 100% more surface area of
cage 104 can be covered with poppet heads 208 as compared to the
prior art, thereby enhancing the fluid control through assembly
102.
[0024] The poppet valve assembly 102 enables more precise control
of fluid flow as compared to conventional poppet valve assemblies
by allowing the use of smaller valves with smaller cross-sectional
fluid flow openings. Because of the relatively small size of the
poppets 112 of the present disclosure as compared to conventional
poppets, a larger number of poppets 112 of the present disclosure
may be disposed in the same dimensional envelope. As a result,
fluid flow may be more precisely controlled.
[0025] In high-speed compressor applications, precise control of
fluid flow is important. The poppet valve assembly 102 may be used
in high-speed compressor applications. In an embodiment, the
high-speed compressor application may require operation at a speed
that is between approximately 600 rpm and approximately 1500 rpm.
In contrast, conventional compressors, using conventional poppet
valve assemblies, are limited to operating at a much slower
relative speed. For example, a conventional compressor using
conventional poppet assemblies might be limited to operating at a
speed that is between approximately 200 rpm and approximately 600
rpm.
[0026] Furthermore, because the poppets 112 include heads 208 that
have a diameter that is larger than the diameter of the respective
through bores 232 the sealing surface 212 and flow window of the
poppets 112 extend beyond the maximum diameter 210 of the stem 204.
One benefit of the foregoing is that it allows for use of a larger
through bore 232 while maintaining a relatively small guiding body.
While the same size and shape heads 208 for the plurality of
poppets 112 is shown in FIG. 1, in other embodiments, the size
and/or shape of the heads 208 may be varied in a poppet valve
assembly 112 to achieve the desired flow characteristics for the
particular compressor with which it is used.
[0027] In conventional poppet valve assemblies, conventional lift
spacers are used as cushions or buffers and are not designed to
control movement of the poppets. In contrast, the lift spacer 220
is designed to control movement of the poppets 112. The lift spacer
220 under the poppet 112 can be customized to vary the clearance
between the sealing surface 112 and the through bore 232, and thus
precisely control fluid flow. In other embodiments, the thickness
of the lift spacers 220 and the dimensions of the head 208 may be
varied depending on the desired fluid flow characteristics across
the plurality of poppets 112 for a particular high speed compressor
application.
[0028] With respect to the poppet valve assembly 102 specifically
shown in FIGS. 1 and 2, the lift spacer 220 that is disposed under
the poppet 112a has substantially the same dimensions as the lift
spacers that are disposed under the poppets 112b-i. However, in
another embodiment, each of the lift spacers that are disposed
under the poppets 112a-i has dimensions that are varied depending
on the desired fluid flow characteristics across the poppets
112a-i. For example, the lift spacer 220 that is disposed under the
poppet 112a may be a different height as compared to a second lift
spacer that is disposed under one of the poppets 112b-i.
[0029] During operation of the poppet valve assembly 102 in a
high-speed compressor, the tight fit of the components of the
poppet valve assembly 102, as compared to conventional poppet valve
assemblies, may cause one or more poppets to become "air locked."
However, the aperture 224 that is disposed in the lift spacer 220
enables back-venting of fluid, thereby preventing the plurality of
poppets 112 from becoming "air-locked."
[0030] Another advantage of embodiments of the present disclosure
is that a standard poppet 112a-i may be utilized for all counter
bores 108a-i, while allowing the flow area through each through
bore 232 to be individually adjusted by varying the thickness of
the lift spacer 220.
[0031] While the system of the invention is best described in the
context of a high speed compressor application, those skilled in
the art will understand that the invention may also be utilized in
other applications where precise control of fluid flow is
required.
[0032] Although only a few exemplary embodiments of this invention
have been described in detail above, those skilled in the art will
readily appreciate that many modifications are possible in the
exemplary embodiments without materially departing from the novel
teachings and advantages of this disclosure.
* * * * *