WO2017196295A1

WO2017196295A1 - Pressure regulator plunger with an integrated check valve

Info

Publication number: WO2017196295A1
Application number: PCT/US2016/031463
Authority: WO
Inventors: Miguel A. MALDONADO
Original assignee: Cummins Inc
Current assignee: Cummins Inc
Priority date: 2016-05-09
Filing date: 2016-05-09
Publication date: 2017-11-16
Anticipated expiration: 2018-11-09

Abstract

A pressure regulator comprising a housing unit having a chamber with an inlet portion and an outlet portion and a pressure relief valve disposed between the inlet portion and a retainer, wherein the retainer is structured to prevent the relief valve from moving past a predetermined longitudinal position and the retainer is structured to allow fluid to pass from the inlet portion to the outlet portion, wherein the pressure regulator does not comprise a spring are disclosed.

Description

PRESSURE REGULATOR PLUNGER WITH AN INTEGRATED CHECK VALVE

FIELD OF THE DISCLOSURE

[0001] This disclosure relates to pressure regulators with integrated check valves. More specifically, this disclosure relates to pressure regulators with integrated check valves that do not have springs and their manufacture.

BACKGROUND

[0002] Pressure regulators are important components in fuel systems, such as a fuel system in a conventional gasoline or diesel engine. The pressure regulator helps to ensure a consistent pressure within the fuel rail and, thus, helps to improve the accuracy and precision of the amount of fuel actually injected into the engine.

[0003] Ensuring that the correct amount of fuel is inj ected into a cylinder helps to ensure that a stoichiometric amount of fuel is in the cylinder during combustion. Stoichiometric amounts of fuel avoid fuel-air ratios that are not too rich or too lean. In cases where the fuel-air ratio is too rich, particulates may increase and result in undesirable levels of emissions. When the fuel-air ratio is too lean, power loss may result and the engine may also experience a surge or may even knock. Knocking may result in engine damage, loss of performance, and decreased longevity of the engine life.

[0004] A need therefore exists to address issues of reducing the cost and complexity.

SUMMARY

[0005] In some embodiments, pressure regulators may comprise a housing unit comprising a chamber having an inlet portion and an outlet portion, a pressure relief valve disposed between the inlet portion and a retainer, wherein the retainer is structured to prevent the relief valve from moving past a predetermined longitudinal position and the retainer is structured to allow fluid to pass from the inlet portion to the outlet portion, wherein the pressure regulator does not comprise a spring.

[0006] In various embodiments, pressure regulators may comprising a housing unit comprising a chamber having an inlet portion and an outlet portion, a pressure relief valve disposed between the inlet portion and a retainer, means for preventing the relief valve from moving past a predetermined longitudinal position, means for allowing fluid to pass from the inlet portion to the outlet portion, and means for biasing the pressure relief valve, wherein the biasing means is not a spring.

[0007] Various embodiments may include methods may also include method of manufacture comprising disposing a pressure relief valve into a housing unit comprising a chamber having an inlet portion and an outlet portion, disposing a retainer into the housing unit, biasing the pressure relief valve without a spring, and coupling the retainer to the housing unit so the pressure relief valve is disposed between the inlet portion and the retainer, wherein the retainer is structured to prevent the relief valve from moving past a predetermined longitudinal position and the retainer is structured to allow fluid to pass from the inlet portion to the outlet portion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above mentioned and other features and objects of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of exemplary embodiments of the disclosure taken in conjunction with the accompanying drawings, wherein:

[0009] FIG. 1A and 2B are perspective views of a pressure regulator plunger with an integrated priming check valve;

[0010] FIG. 2A is a front view of a pressure regulator plunger with an integrated priming check valve;

[0011] FIG. 3 is an exploded, perspective view of a pressure regulator plunger with an integrated check valve;

[0012] FIG. 4 is cross-sectional view of a pressure regulator plunger with an integrated priming check valve; and

[0013] FIG. 5 is a flowchart of a method of manufacture of a pressure regulator plunger with integrated priming check valve.

[0014] Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present disclosure. The exemplification set out herein illustrates exemplary embodiments of the disclosure, in various forms, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner. DETAILED DESCRIPTION

[0015] The embodiment disclosed below is not intended to be exhaustive or limit the disclosure to the precise form disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize its teachings.

[0016] FIGs. 1A and IB illustrate perspective views of a pressure regulator plunger with integrated check valve. Pressure regulator plunger 100 may comprise a housing unit 110 which may include a chamber (shown in FIG. 4) having an inlet portion 120 and an outlet portion 130. Pressure regulator plunger 100 may also include a pressure relief valve 150 disposed between the inlet portion 120 and a retainer (shown in FIGs. 2, 3, and 4 as 160). With temporary reference to FIG. 4, the retainer 160 may be structured to prevent the relief valve 150 from moving past a predetermined longitudinal position (e.g., past the position of the retainer 160), while the inlet housing 190 may be structured to prevent the relief valve from moving past a predetermined longitudinal position proximate inlet portion 120.

[0017] In various embodiments, inlet housing may comprise an inner angled surface 1 13, which may allow for relief valve to seat against inlet housing 190. Inner angled surface 1 13 may comprise various angles and is not particularly limited. In embodiments where the inner wall of the housing unit is substantially annular, inner angled surface 1 13 may be substantially frustoconical, as exemplified in FIG. 4.

[0018] Furthermore, in various embodiments, inlet housing 190 and housing unit 110 may form an integral piece, for example, as illustrated in FIG. 4.

[0019] Also, the retainer 160 may be structured to allow fluid to pass from the inlet portion 120 to the outlet portion 130. As shown in FIGs. 1-4, the pressure regulator does not comprise a spring and, thus, may be preferable to other conventional pressure regulator plungers because of reduced costs, improved robustness, and a reduction of internal components. Furthermore, the pressure regulator plunger 100 may comprise relief holes 140 for ease of handling during manufacture or installation.

[0020] FIG. 1A shows the pressure relief valve 150 in an over-pressure configuration. This configuration may occur when the fuel pressure exceeds certain thresholds. In various embodiments, fuel is then allowed to flow from the inlet 120 around the pressure relief valve 150 and through outlet 130. In some embodiments, for example, fuel that passes through the outlet 130 may be redirected back to the fuel pump. [0021] FIG. 2A is a front view of the pressure regulator plunger 100 with the inlet housing 190 and priming valve 150 removed. FIG. 2B is a front view of the pressure regulator plunger 100 with the inlet housing 190 and pressure relief valve 150 in an exemplary configuration.

[0022] As can be seen in FIG. 2A, retainer 160 may be structured to allow fluid to pass from the inlet portion 120 to the outlet portion 130. For example, in various embodiments, retainer 160 may be structured to allow fluid flow between an outer portion of the retainer and an inner wall of the housing unit. For example, retainer 160 may include flat flow areas 165 along an outer surface of retainer 160 as exemplified in FIG 2 A and FIG. 3. Thus, this configuration constitutes an exemplary means for allowing the fluid to pass from inlet portion 120 to outlet portion 130.

[0023] Also, the retainer 160 may be substantially cylindrical in shape (except for flat flow areas 165), as shown in FIG. 3, which is an exploded view of pressure regulator plunger 100. In this embodiment, retainer 160 also comprises rounded portions 167, which may be configured to engage with the inner wall 115 (shown in FIG. 4) of housing unit 110.

[0024] However, retainer 160 is not particularly limited and may include any shape or other means for allowing fluid to pass from the inlet portion to the outlet portion. For example, in various embodiments, retainer 160 may be structured to allow fluid to flow though the retainer (e.g., through a hole or plurality of holes) or past the retainer in one or more grooves formed on the outer surface of retainer 160.

[0025] FIG. 4 is a cross-sectional view of a pressure regulator plunger 100 with an integrated check valve. As can be seen in FIG. 4, housing unit 110 may include a chamber 111. In various embodiments— and as exemplified in FIG. 4— the inner wall 115 of the chamber 111 may be form a substantially cylindrical bore (e.g., where retainer 160 is substantially

cylindrical).

[0026] In various embodiments, pressure relief valve 150 may be configured to move longitudinally along inner wall 115 of chamber 111. Thus, pressure relief valve may be a variety of shapes and is not particularly limited. For example, in various embodiments, pressure relief valve 150 may be spherical, such as a sphere, a sphere with tiling, or spheroid (e.g., a prolate, an oblate, etc.). Other exemplary geometries for pressure relief valve 150 include a toms, a cone, or a pyramid.

[0027] Furthermore, the material of pressure relief valve 150 is also not particularly limited. In various embodiments, pressure relief 150 valve may comprise a metal, plastic/rubbers, or combinations thereof. Exemplary metals include aluminum, tungsten, platinum, iridium, rhodium, nickel, copper, zinc, cadmium, silver, gold, iron, ruthenium, molybdenum, alloys thereof, or combinations thereof. Exemplary plastics/rubbers include fiuoroelastomers (FKM), perfluoro-elastomers (FFKM), tetrafluoro ethylene/propylene rubbers (FEPM), or mixtures thereof.

[0028] In various embodiments, pressure relief valve 150 may be biased towards inlet portion 120 of chamber 1 15 of inlet housing 190. Thus, pressure relief valve 150 may be configured to move longitudinally towards outlet portion 130, in response to the pressure near inlet portion 120 of pressure regulator plunger 100 reaching a threshold value. When pressure relief 150 valve moves towards outlet portion 130 of pressure regulator plunger 100, a flow path may be created, relieving the overpressure in the fuel system, for example, in an engine.

[0029] Also disclosed herein are pressure regulators having a housing unit comprising a chamber having an inlet portion and an outlet portion, a pressure relief valve disposed between the inlet portion and a retainer, means for preventing the relief valve from moving past a predetermined longitudinal position, means for allowing fluid to pass from the inlet portion to the outlet portion, and means for biasing the pressure relief valve, wherein the biasing means is not a spring.

[0030] For example, FIG. 4 illustrates pressure regulator 100 having a housing unit 110 comprising a chamber 11 1 having an inlet portion 120 and an outlet portion 130, a pressure relief valve 150 disposed between the inlet portion 120 and a retainer 160, means for preventing the relief valve from moving past a predetermined longitudinal position, means for allowing fluid to pass from the inlet portion 120 to the outlet portion 130, and means for biasing the pressure relief valve, wherein the biasing means is not a spring.

[0031] The biasing means are not particularly limited and may include magnetic means, gravitational means, or a combination thereof. For example, in some embodiments, part of the housing unit 110 near inlet portion 120 may comprise magnetic material and pressure relief valve 150 may comprise ferromagnetic material, biasing pressure relief valve 150 near inlet portion 120 (e.g., in a closed position).

[0032] In some embodiments, the pressure regulator may include a housing unit including a chamber having an inlet portion and an outlet portion, a pressure relief valve disposed between the inlet portion and a retainer, wherein the retainer is structured directly communicate with the pressure relief valve to prevent the relief valve from moving past a predetermined longitudinal position and the retainer is structured to allow fluid to pass from the inlet portion to the outlet portion. [0033] Furthermore, in some embodiments, the pressure relief valve may be biased to the inlet portion of the housing unit, for example, in some embodiments, in the closed position.

[0034] FIG. 5 illustrates a method for manufacturing of a pressure regulator plunger with an integrated check valve. Method 500 may include disposing a pressure relief valve into a housing unit comprising a chamber having an inlet portion and an outlet portion (step 510), disposing a retainer into the housing unit (step 520), biasing the pressure relief valve without a spring (step 530), and coupling the retainer to the housing unit (step 540) so the pressure relief valve is disposed between the inlet portion and the retainer, wherein the retainer is structured to prevent the relief valve from moving past a predetermined longitudinal position and the retainer is structured to allow fluid to pass from the inlet portion to the outlet portion.

[0035] Method 500 is not particularly limited and may include any of the various embodiments of pressure relief valves, housing units, and/or retainers disclosed herein. For example, step 510 may include disposing a pressure relief valve into a housing unit where the pressure relief valve comprises a fiuoroelastomer (FKM), perfiuoro-elastomers (FFKM), tetrafluoro ethylene/propylene rubbers (FEPM), aluminum, tungsten, platinum, iridium, rhodium, nickel, copper, zinc, cadmium, silver, gold, iron, ruthenium, molybdenum, alloys thereof, or combinations thereof.

[0036] While this disclosure has been described as having an exemplary design, the present disclosure may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains.

[0037] Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements. The scope is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more." Moreover, where a phrase similar to

"at least one of A, B, or C" is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B or C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.

[0038] In the detailed description herein, references to "one embodiment," "an

embodiment," "an example embodiment," etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art with the benefit of the present disclosure to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

[0039] Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. § 112(f), unless the element is expressly recited using the phrase "means for." As used herein, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Claims

WHAT IS CLAIMED IS :

1. A pressure regulator comprising:

a housing unit comprising a chamber having an inlet portion and an outlet portion; a pressure relief valve disposed between the inlet portion and a retainer, wherein the retainer is structured to prevent the relief valve from moving past a predetermined longitudinal position and the retainer is structured to allow fluid to pass from the inlet portion to the outlet portion, wherein the pressure regulator does not comprise a spring.

2. The pressure regulator of claim 1, wherein the retainer is structured to allow fluid flow between an outer portion of the retainer and an inner wall of the housing unit.

3. The pressure regulator of claim 2, wherein the inner wall of the housing unit is substantially annular.

4. The pressure regulator of claim 3, wherein the chamber is substantially cylindrical.

5. The pressure regulator of claim 4, wherein the retainer comprises flat flow areas along an outer surface of the retainer.

6. The pressure regulator of claim 1, wherein the retainer is structured to allow fluid to flow though the retainer.

7. The pressure regulator of claim 6, wherein the retainer is substantially annular.

8. The pressure regulator of claim 1, wherein the pressure relief valve is spherical.

9. The pressure regulator of claim 1, wherein the pressure relief valve comprises a metal.

10. The pressure regulator of claim 9, wherein the metal comprises aluminum, tungsten, platinum, iridium, rhodium, nickel, copper, zinc, cadmium, silver, gold, iron, ruthenium, molybdenum, alloys thereof, or combinations thereof.

11. The pressure regulator of claim 1, wherein the pressure relief valve is biased towards the inlet portion of the chamber of the housing unit.

12. The pressure regulator of claim 1, wherein the pressure relief valve comprises a fluoroelastomer (FKM), perfluoro-elastomers (FFKM), tetrafluoro ethylene/propylene rubbers (FEPM), or mixtures thereof.

13. The pressure regulator of claim 12, wherein the pressure relief valve comprises vinylidene fluoride (VDF) and hexafluoropropylene (HFP), tetrafluoroethylene (TFE), perfluoromethylvinylether (PMVE), propylene, ethylene, or mixtures thereof.

14. An engine comprising the pressure regulator of claim 1.

15. The pressure regulator of claim 1, wherein the inlet portion comprises an inner angled surface.

16. The pressure regulator of claim 15, wherein the inner angled surface is substantially frustoconical.

17. A pressure regulator comprising:

a housing unit comprising a chamber having an inlet portion and an outlet portion;

a pressure relief valve disposed between the inlet portion and a retainer;

means for preventing the relief valve from moving past a predetermined longitudinal position;

means for allowing fluid to pass from the inlet portion to the outlet portion; and means for biasing the pressure relief valve, wherein the biasing means is not a spring.

18. The pressure regulator of claim 17, wherein the biasing means are magnetic, gravitational, or a combination thereof.

19. The pressure regulator of claim 17, wherein the pressure relief valve comprises a fluoroelastomer (FKM), perfluoro-elastomers (FFKM), tetrafluoro ethylene/propylene rubbers

(FEPM), aluminum, tungsten, platinum, iridium, rhodium, nickel, copper, zinc, cadmium, silver, CI-14-0256-01 -WO-E gold, iron, ruthenium, molybdenum, alloys thereof, or combinations thereof.

20. The pressure regulator of claim 17, wherein the means for allowing the fluid to pass from the inlet portion to the outlet portion comprise allowing fluid flow between an outer portion of the retainer and an inner wall of the housing unit.

21. A method of manufacture comprising:

disposing a pressure relief valve into a housing unit comprising a chamber having an inlet portion and an outlet portion;

disposing a retainer into the housing unit;

biasing the pressure relief valve without a spring; and

coupling the retainer to the housing unit so the pressure relief valve is disposed between the inlet portion and the retainer, wherein the retainer is structured to prevent the relief valve from moving past a predetermined longitudinal position and the retainer is structured to allow fluid to pass from the inlet portion to the outlet portion.

22. The method of claim 21 , wherein the pressure relief valve comprises a fluoroelastomer (FKM), perfluoro-elastomers (FFKM), tetrafluoro ethylene/propylene rubbers (FEPM), aluminum, tungsten, platinum, iridium, rhodium, nickel, copper, zinc, cadmium, silver, gold, iron, ruthenium, molybdenum, alloys thereof, or combinations thereof.