AU2015254984A1

AU2015254984A1 - Compressor valve

Info

Publication number: AU2015254984A1
Application number: AU2015254984A
Authority: AU
Inventors: Michael Boken
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-05-02
Filing date: 2015-05-01
Publication date: 2016-12-15
Also published as: WO2015166335A2; WO2015166335A3

Abstract

A one-way fluid valve generally referred to as a "reed" type valve includes a valve module which may be deployed as part of a valve assembly. The valve module includes a body with at least one fluid channel, a plate providing a fluid seal across the fluid channel, and a biasing element, which provides a biasing force to releasably retain the plate in a fluid sealing relation across the fluid channel. More specifically, the plate is disposed in a hinging relation across the fluid channel, and at least one spring provides a biasing force against the plate. When the pressure on the inlet side of the valve is great enough to overcome the biasing force, the plate hinges open, breaking the seal, and allowing the pressure on both sides of the plate to equalize.

Description

COMPRESSOR VALVE BACKGROUND OF THE INVENTION Field of the Invention

The invention is directed to one-way fluid valves and more specifically, valve modules which may be disposed in valve assemblies.

DESCRIPTION OF THE RELATED ART A check valve is a mechanical component which generally only allows the passage of a fluid therethrough in one direction. Check valves can be arranged in various configurations including what is known as a reed valve. A reed valve generally contains a body through which fluid is allowed to flow and a "flapper" or "petal" which overlies an opening in or on the body to create a seal thereon. The flapper is mounted to the body in such a fashion as to allow it to deflect when the pressure is greater on the inlet side than on the outlet side. This deflection breaks the seal created by the overlying disposition and allows fluid to flow through the valve, equalizing pressure on the inlet and outlet sides. Once the pressure on both sides of the valve has reached an equilibrium, or the net force on the flapper is no longer great enough to overcome the retaining force on the flapper, it returns to its overlying position and re-establishes a seal across the opening. The flapper is further mounted such that, should the pressure on the outlet side be greater than the pressure on the inlet side, the flapper will not deflect, and therefore, fluid will not be allowed to flow from the outlet side to the inlet side.

Generally, the flapper is rigidly mounted in an overlying fashion across the opening. Therefore, the resistance to deflection is dictated by the bending stiffness of the flapper. In other words, when the pressure on the inlet side produces a force on the flapper which is great enough to overcome the bending stiffness of the flapper, the flapper deflects, which induces strain in the flapper. When a reed valve is utilized in a mechanism such as a gas compressor, which requires hundreds or perhaps even thousands of openings every minute, avoiding fatigue induced failure is a top concern when designing a flapper. Furthermore, the flapper must be precisely formed or else it will not form a sufficient seal across the opening. This makes flappers relatively expensive to manufacture and replace. By transferring the strain to another element of the valve which can be cheaply and readily made, such as a standardized spring or other biasing element, running costs of the valve can be greatly reduced. This is because the wear and tear normally afflicted on the flapper can be substantially transferred to a less precise and less expensive element, which can be replaced at lower cost.

Furthermore, current flapper mounting techniques require that the flapper be substantially supported by the body of the valve, leaving a relatively small surface area over which the pressurized fluid can act to deform the flapper. Because the fluid is acting over a small surface area, a greater force is developed over that surface area and the opportunity for plastic deformation, or even catastrophic failure, of the flapper is increased. By taking advantage of a novel mounting technique provided by the invention as disclosed herein, a relatively larger portion of the surface area of the flapper can be presented to the pressurized fluid, thereby decreasing the force which develops over that surface area, and decreasing the opportunity for plastic deformation or catastrophic failure of the flapper. This and other problems faced in the related art are solved by the present invention as will be further disclosed below.

SUMMARY OF THE INVENTION

The present invention generally relates to a novel valve module which may be disposed, along with a plurality of other valve modules of substantially similar construction, in a valve assembly. The valve assembly may then be deployed in its desired use, such as, for example, as part of a gas compressor.

The valve module includes a body, the body including at least one fluid channel disposed between at least one inlet aperture and at least one outlet aperture. Disposed in the fluid channel, or at least across the fluid channel, is at least one plate. The plate may be in contact with a plate interface surface of the body so as to form a seal, preferably preventing or at least significantly restricting the free flow of fluid through the fluid channel. A biasing element may be provided to assist in retaining the plate against the plate interface surface. In operation as a valve, it will be desirable that the valve open and that the plate retreat from its sealing relation against the plate interface surface. Hence, the biasing element may be selected to optimize the characteristics of the valve opening event, such as the amount of pressure on the inlet aperture side of the plate required to overcome the biasing force provided by the biasing element. Other characteristics, such as a dampening character of the biasing element may be selected and desired, to reduce a vibration of the plate or biasing element.

The plate may include at least one plate retention member, configured to securely retain the plate in such a fashion as to make opening of the valve repeatable and precise. This may be accomplished, for example, by a curved plate retention member that interlocks with corresponding structure on a wall in a hinge-type relation, thereby providing the plate a fixed point about which to hinge. A few alternative embodiments of the valve module are disclosed herein which include bodies with differing shapes, such as one with a circular cross section. Accordingly, the plates and other components are modified to operate within such a circular body. Another embodiment includes an arched body, such as to make packing in a valve assembly more efficient.

Also disclosed is one embodiment of a valve assembly into which the valve modules may be disposed. The embodiment includes an inlet plate and an outlet plate, each plate including a plurality of inlet apertures and a plurality outlet apertures, respectively. The inlet plate and outlet plate are correspondingly configured and dimensioned to include a plurality of valve cavities between corresponding inlet apertures and outlet apertures. The valve modules may be disposed into the valve cavities, the inlet and outlet plates'joined together, and the valve assembly deployed for use in, for example, a gas .compressor.

The valve module may also include a number of other structures and features which enhance the operation, durability, longevity, or maintenance of the invention. These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

Figure 1 is a perspective view of a valve module in accordance with one embodiment of the present invention.

Figure 2 is a top plan view of a valve module in accordance with one embodiment of the present invention.

Figure 3 is a bottom plan view of a valve module in accordance with one embodiment of the present invention

Figure 4 is a front plan section view of a valve module in accordance with one embodiment of the present invention

Figure 5 is a perspective view of a body of a valve module in accordance with one embodiment of the present invention

Figure 6 is a top plan view of a body of a valve module in accordance with one embodiment of the present invention.

Figure 7 is a perspective view of a plate of a valve module in accordance with one embodiment of the present invention.

Figure 8 is a side plan view of a plate of a valve module in accordance with one embodiment of the present invention.

Figure 8A is a front plan view of a plate of a valve module in accordance with another embodiment of the present invention.

Figure 8B is a side plan view of a plate of a valve module in accordance with the embodiment depicted in Figure 8A.

Figure 9 is a perspective view of a wall of a valve module in accordance with one embodiment of the present invention.

Figure 10 is a perspective view of a valve assembly including a plurality of valve modules in accordance with one embodiment of the present invention.

Figure 11 is a side plan section view of a valve assembly including a plurality of valve modules in accordance with one embodiment of the present invention.

Figure 12 is a front plan section view of a valve module including a "V" shaped biasing element in accordance with one embodiment of the present invention.

Figure 13 is a perspective view of a valve module in accordance with one embodiment of the present invention.

Figure 14 is a font section plan view of a valve module in accordance with one embodiment of the present invention.

Figure 15 is a bottom plan view of a valve module in accordance with one embodiment of the present invention.

Figure 16 is top plan view of a valve module in accordance with one embodiment of the present invention.

Figure 17 is a perspective view of a valve module in accordance with one embodiment of the present invention.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is directed toward a valve module 10 which may be removably disposed in a valve assembly 1000. With reference, generally, to Figs. 1-5, the invention includes a body 100. The body includes at least one inlet aperture 110 and at least one outlet aperture 120. At least one fluid channel 105, through which a fluid may flow in operation of the valve module 10, connects each inlet aperture 110 and outlet aperture 120. The body 100 may be constructed of any of a variety of relatively durable materials including, but not limited to, plastics, composites, metals, and alloys. More specifically, in at least one embodiment the body 100 is constructed of a polyamide such as nylon. In further embodiments the body 100 may be made of a carbon fiber or glass fiber reinforced polymer composite.

The inlet aperture 110 may include at least one inlet cross member 111, thereby creating a plurality of inlet apertures 120. One or more inlet cross members 111 may be desirable to help control the flow of fluid through the valve module 10, or to increase the structural strength of the body 100.

With reference to Figs. 4 through 8, a plate interface surface 130 may be disposed in a fluid channel 105 of the body 100. The plate interface surface 130 should be cooperatively structured and dimensioned with at least one plate 200, such that when a plate 200 is overlaid the plate interface surface 130, a fluid seal is formed, thereby restricting, or at least impeding, the flow of fluid through a fluid channel 105 of the body 100. A body interface surface 210 of the plate 200 may be formed as a substantially flat and rigid member, so as to reduce the likelihood of an unintended passage of fluid between the plate 200 and plate interface surface 130, such as by a leak therefrom. It is also desirable that the plate 200 be durable as well, as the plate 200 may be subject to high cyclic loadings in use. In at least one embodiment, the desired durability of the plate 200 may be accomplished by forming the plate 200 from a martensitic steel.

An alternative embodiment of a plate 200 is depicted in Figs. 8A and 8B wherein a sealing lip 240 is disposed on the body interface surface 210. As such, the sealing lip 240 will further facilitate a sealing relation of the plate 200 against the plate interface surface 130 of the body 100 (depicted in Fig. 5).

Now with reference to Figs. 4, 5, 6, and 9, in order to reliably dispose the plate 200 in sealing relation to the plate interface surface 130, a support member 140 may be disposed within the body 100 or fluid channel 105. Accordingly, the plate 200 and support member 140 may include appropriate structuring to seat the plate 200 in the support member 140, as well as appropriate structuring to allow the plate 200 to pivot or hinge upon the support member 140. This may be accomplished by providing a curved plate retention member 230 on the plate 200 which sits in a correspondingly shaped plate retention seat 142 in the support member 14 0, as depicted in Fig. 4. Additional embodiments may include a gasket disposed on the plated interface surface 130 to further facilitate the sealing relation.

In at least one embodiment the support member 14 0 may be formed unitarily with the body 100. The support member 140 may also include at least one fluid directing element 143. As depicted in Fig. 4, the fluid directing element 143 may comprise an at least partially aerodynamic form on the side of the support member 140 proximal to the inlet aperture 110. Thus deployed, the fluid directing element 143 can contribute to the control of fluids flowing through the valve module 10. It may also be desirable to add at least one rib member 150 in supporting relation to the support member 140. With reference to the body 100 as depicted in Figs. 4 and 5, the rib members 150 may also define a portion of the plate interface surface 130. Furthermore, the rib members 150 may be formed unitarily with the inlet cross members 111 so as to form a plurality of fluid channels 105 within the body 100. Lastly, the body 100, support member 140, rib members 150, and inlet cross members 111 may be formed unitarily, such as by injection molding or additive manufacturing. Alternatively, the body 100, support member, 140, rib members 150, and inlet cross members 111 may be formed individually, and assembled.

In operation of the valve module 10 in, for example, a gas compressor, it may be desirable that fluid only be allowed to flow between the plate 200 and the plate interface surface 130 once a desired pressure has been achieved on the inlet aperture 110 side of the valve module 10. Thus, as represented in Fig. 4, a biasing element 400 may be provided to provide a biasing force on the plate 200 which retains the plate 200 against the plate interface surface 130 until such pressure is high enough to overcome the biasing force of the biasing element 400. As embodied in Fig. 4, the biasing element 400 is a coil spring disposed between two plates 200. It will be appreciated, however, that the biasing element 400 depicted in Fig. 4 is not the only acceptable method of providing a biasing force on the plate 200.

As a non-limiting example, the biasing element 400' as depicted in Fig. 12 may be provided, whereby a substantially "V" shaped and flexible member is provided between the two plates 200. In such an embodiment, the biasing element 400' may be made from, for example, spring steel, and stamped and bent into an appropriate shape. Other embodiments may include fabrication from fiber reinforced polymer composite. Accordingly, the biasing element aperture 320' is appropriately conformed to retain the biasing element 400' as well. Yet further embodiments of a biasing element may comprise a torsion spring or other elastic member, such as a rubber sphere.

In order to securely retain the biasing element 400 against the plate 200, it may be desirable to provide a biasing element retention member 220 on the plate 200 as structuring to which the biasing element 400 may be affixed to. As depicted in Figs. 4 and 7, the biasing element retention member 220 may be formed as a protrusion from the surface of the plate 200, around which a coil spring may be situated. It will be appreciated that differing embodiments of the biasing element 400 may require differing structural arrangements of the biasing element retention member 220. As a non-limiting example, the biasing element retention member may comprise a notch or other indentation into the surface of the plate 200 to accommodate the proximal end of a substantially "v" shaped biasing element 400.

It may also be desirable, to further stabilize and retain the biasing element 400, to provide a wall 300 within the valve module 10. The wall 300 may also act as a stop for the plate 200 to prevent the plate 200 from opening too widely. As depicted in Figs. 4 and 9, the wall 300 may include a primary wall retention member 330, cooperatively structured and dimensioned to be disposed in a primary wall retention seat 141 of the support member 140. Accordingly, the wall 300 may also include at least one plate retention member recess 310 cooperatively structured and dimensioned to be disposed over the plate retention member 230 of the plate 200, and provide a rotatably secure retention thereof .

With reference to Figs. 1, 5, and 9, to further retain and stabilize the wall 300, it may include a secondary wall retention member 340 cooperatively structured and dimensioned to be disposed in a secondary wall retention seat 160 of the body 100.

The wall 300 may also include at least one biasing element aperture 320, through which the biasing element 400 may be projected, as depicted in Fig 4. In some embodiments the biasing element aperture 320 may comprise a through-hole, and in some embodiments the biasing element aperture may comprise a blind-hole in one side of the wall 300. In an embodiment with a blind-hole, multiple biasing elements 400 may be provided with differing overall lengths or, in other embodiments, differing spring rates, thereby allowing a plurality of plates 200 to open relative to differing pressures. In yet further embodiments, the wall 300 may include a biasing element aperture shroud 321 to further stabilize the biasing element 400 or act as a stop for a plate 200.

As stated above, the present invention is directed toward a valve module 10 which may be deployed as part of a valve assembly 1000. One embodiment of such a valve assembly 1000 is depicted in Figs. 10 and 11. Provided is an inlet plate 1100 and an outlet plate 1200. The inlet plate 1100 includes a plurality of inlet plate apertures 1110 and the outlet plate 1200 includes a plurality of outlet plate apertures 1210. The inlet plate 1100 and outlet plate 1200 are cooperatively structured and dimensioned so as to form a plurality of valve cavities 1300 disposed between corresponding inlet plate apertures 1110 and outlet plate apertures 1210.

Each or at least a majority of the valve cavities 1300 are cooperatively structured and dimensioned with different ones of the valve module 10 so as to provide a secure fitment of the valve module 10 within the valve cavity 1300. Furthermore, the body 100 of the valve module 10 may include at least one body retention surface 170 to mate with a corresponding structure on the outlet plate 1200, such as a body retention member 1230 to retain the valve module 10 within the valve cavity 1300. It will be appreciated that, in such an embodiment, the valve module 10 requires no fastening members to retain each member therein. As depicted in Fig. 11, the body retention member 1230 provides a retaining force against the secondary wall retention member 340, which retains the wall 300, and in turn, retains the biasing element 400 as well as a plurality of plates 200 disposed therein. Thus, it will be further appreciated, that the present invention provides a valve module 10 which may be assembled without need for fastening members, and which may further be deployed in any orientation, including upside down, without unintended disassembly.

Once a plurality of valve modules 10 are disposed within corresponding valve cavities 1300, the inlet plate 1100 and outlet plate 1200 may be mated and correctly aligned with reference to a plate alignment recess 1120 and corresponding plate alignment notch 1220. Then, the inlet plate 1100 and outlet plate 1200 may be secured together with at least one fastener 1400. It will be appreciated that any of a number of appropriate fasteners 1400 may be deployed, other than those depicted in Fig. 9 .

With reference to Figs. 13, 14, and 15, depicted is one embodiment of a valve module 10' including a body 100' with substantially circular cross section. In this embodiment, at least one inlet cross member 111 may be provided in supporting relation of a support member 140 attached thereto and disposed longitudinally along a fluid channel 105 of the body 100' . A plurality of substantially curved plates 200' are disposed in a fluid channel, which may be attached to the support member 140 at or near the inlet aperture 110. The plurality of plates 200' extend along the length of the fluid channel 105 and seal against a plate interface surface 130 at or near the outlet aperture 120, which may comprise a portion of the interior surface 180 of the body 100'. At least one biasing element 400 is disposed between the support member 140 and each of the plurality of plates 200.

With reference to Figs. 16 and 17, a substantially curved or arched body 100" may be provided for more efficient packing of the valve module 10" into a valve assembly 1000. As depicted, the valve module 10" may only comprise one fluid channel 105, one plate 200", and one biasing element 400. The plate 200" may be substantially flat, even though the body 100" includes a curve, provided that the plate interface surface 130 is correspondingly structured with the substantially flat plate 200" to provide a fluid seal across the fluid channel 105. Alternatively, the plate 200" may be curved correspondingly with the curve of the body 100" in order to be disposed in a sealing relation against a plate interface surface 130 that may comprise an interior surface 180 of the body 100.

Since many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.

Now that the invention has been described,

Claims

What is claimed is:

1. A valve module comprising: a body comprising at least one inlet aperture and at least one outlet aperture oppositely disposed and at least one fluid channel therebetween; said one fluid channel comprising a plate interface surface; at least one plate disposed in a sealing relation to said plate interface surface thereby restricting a flow of fluid through said fluid channel; and at least one biasing element having a predetermined biasing force, said biasing element disposed in biasing relation to said one plate, said predetermined biasing force being sufficient to releasably retain said one plate in sealing relation to said plate interface surface.
2. The valve module as recited in claim 1 further comprising a support member disposed in said fluid channel; said support member comprising at least one plate retention seat and at least one primary wall retention seat.
3. The valve module of claim 2 wherein said support member further includes at least one fluid directing element.
4. The valve module as recited in claim 2 wherein said one plate further comprises at least one plate retention member; said one plate retention seat structured and dimensioned to receive said one plate retention member.
5. The valve module as recited in claim 4 further comprising at least one rib member disposed in supporting relation between said support member and said outlet aperture.
6. The valve module as recited in claim 4 further comprising a wall including at least one primary wall retention member and at least one plate retention member recess; said one plate retention member recess disposed over said one plate retention member of said plate and said one primary wall retention member disposed in said one wall retention seat of said support member, movably retaining said one plate retention member in said one plate retention seat.
7. The valve module as recited in claim 5 wherein said one rib member at least partially defines said plate interface surface.
8. The valve module as recited in claim 6 wherein said wall further comprises at least one biasing element aperture, said biasing element at least partially disposed therethrough.
9. The valve module as recited in claim 8 wherein said wall further includes a biasing element aperture shroud projecting from said biasing element aperture.
10. The valve module as recited in claim 1 wherein said one plate further comprises a biasing element retention member disposed thereon.
11. The valve module as recited in claim 1 wherein said inlet aperture further comprises at least one inlet cross member disposed transversely across said inlet aperture.
12. The valve module as recited in claim 1 further including at least one other plate, at least one other plate interface surface, and at least one other biasing element; said one other plate disposed in sealing relation to said one other plate interface surface; said one other biasing element having a predetermined biasing force; said one other biasing element disposed in biasing relation to said one other plate; said predetermined biasing force being sufficient to releasably retain said one plate in sealing relation to said one other plate interface surface.
13. The valve module as recited in claim 1 wherein said fluid channel comprises a substantially circular cross section.
14. The valve module as recited in claim 13 wherein said at least one plate is dimensioned and configured to conform to said substantially circular cross section of said fluid channel in a sealing relation thereto.
15. A valve module comprising a body comprising at least one inlet aperture and at least one outlet aperture oppositely disposed a fluid channel therebetween; a support member disposed transversely across said fluid channel; said support member further comprising at least one primary wall retention seat and at least one plate retention seat; a plurality of rib members disposed in said fluid channel and in supporting relation between said body and said support member; said plurality of rib members at least partially defining a plurality of plate interface surfaces; a plurality of inlet cross members disposed transversely across said inlet aperture; each of said inlet cross members formed integrally with a corresponding one of said plurality of rib members; a plurality --of plates disposed in sealing relation to corresponding ones of said plurality of plate interface surfaces; a wall disposed between said plurality of plates and comprising at least one biasing element aperture; at least one biasing element disposed at least partially through said at least one biasing element aperture; and at least one end of said one biasing element in contact with at least one of a biasing element retention member disposed on at least one of said plurality of plates.
16. A valve module comprising: a body comprising an inlet aperture and an outlet aperture oppositely disposed a fluid channel therebetween; at least one inlet cross member disposed across said inlet aperture in supporting relation to a support member disposed in said fluid channel and attached to said one inlet cross member; a plurality of plates disposed in sealing relation between said support member and a plate interface surface; said plate interface surface comprising an interior surface of said body; at least one biasing element having a predetermined biasing force; said one biasing element disposed in biasing relation to each of said plurality of plates; and said predetermined biasing force being sufficient to releasably retain said plurality of plates in sealing relation between said support member and said plate interface surface.
17. A valve assembly comprising: said valve assembly comprising a plurality of valve cavities; a plurality of valve modules, each valve module removably mounted in a different one of said plurality of valve cavities; each of said valve modules including a body, each of said bodies comprising at least one inlet aperture and at least one outlet aperture oppositely disposed and at least one fluid channel therebetween; each of said fluid channels comprising a plate interface surface; each of said bodies including at least one plate disposed in a sealing relation to said plate interface surface thereby preventing a flow of fluid through said fluid channel; each of said valve modules further including at least one biasing element having a predetermined biasing force; each of said biasing elements disposed in biasing relation to each of said one plates; and said predetermined biasing force being sufficient to releasably retain each of said one plates in sealing relation to each of said plate interface surfaces.