HK1262505A1 - Diaphragm valve - Google Patents

Description

Diaphragm valve

Technical Field

The present disclosure relates to solenoid operated valves, and more particularly to solenoid operated valves sealed by a diaphragm.

Background

This section provides background information related to the present disclosure that is not necessarily prior art.

Solenoid operated valves, such as poppet valves, may be used to control the flow of a fluid, such as compressed air, through the manifold. Such a manifold may be part of an apparatus, such as a sorting machine, a packaging machine, a food processor, etc., driven by a compressed fluid. Such solenoid operated valves may operate millions of times. To maintain the solenoid operated valve in the closed position when the solenoid is de-energized, a biasing member such as a spring is used. It is also known, for example, in U.S. patent No. 4,598,736 to chord, that fluid pressure may be balanced within a valve to reduce the electromagnetic force required to move a valve member between a closed position and an open position.

The valve member is slidably disposed within the valve body barrel. In the closed position, the valve member is normally held in contact with the valve seat of the valve body barrel by the biasing member. In the open position, the solenoid typically moves the valve member away from the valve seat, creating a clearance gap. As disclosed in Paulsen, U.S. patent 3,985,333, a corrugated diaphragm may be used to provide a seal between the valve body barrel and the solenoid. Such a diaphragm prevents contaminants from approaching the solenoid while allowing the valve member to move longitudinally.

The valve body cartridge is designed to be received in a bore provided in the manifold. The manifold typically includes a plurality of passageways disposed in fluid communication with the manifold bore. In operation, the solenoid-operated valve controls fluid flow between the plurality of passageways. An O-ring seal is typically provided on the outside of the valve body barrel to seal the valve body barrel within the manifold bore.

Disclosure of Invention

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

The present invention provides an improved diaphragm valve that includes an electromagnet and a valve body cartridge connected to the electromagnet. The coil, pole piece and armature are located in an electromagnet. The armature is slidable within the electromagnet along the longitudinal axis between an energized position and a de-energized position. A valve member is also disposed within the valve body barrel. The valve member is connected to the armature and is slidable within the valve body barrel when the armature moves between the energized position and the de-energized position. A biasing member, which normally acts to bias the armature to the de-energized position, is also provided in the electromagnet. The diaphragm extends inwardly from the valve body barrel toward the valve member. The diaphragm is received between the armature and the valve member such that the diaphragm deflects as the armature and the valve member move along the longitudinal axis.

The diaphragm valve also includes a diaphragm support sleeve. The diaphragm support sleeve has a support sleeve wall and a support sleeve flange. The support sleeve wall defines a sleeve cavity that receives at least a portion of the armature. The support sleeve flange extends inwardly and transversely to the support sleeve wall. The support sleeve flange abuts and supports at least a portion of the diaphragm.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a side cross-sectional view of an example manifold and an example diaphragm valve according to the present disclosure;

FIG. 2 is a front perspective view of the exemplary diaphragm valve shown in FIG. 1;

FIG. 3 is a side cross-sectional view of the example diaphragm valve of FIG. 1, with the armature of the example diaphragm valve in a de-energized position; and

FIG. 4 is another side cross-sectional view of the example diaphragm valve shown in FIG. 1, with the armature of the example diaphragm valve in an energized position.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Detailed Description

Exemplary embodiments will now be described more fully with reference to the accompanying drawings. The exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be understood as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It will also be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to" or "coupled to" another element or layer, it can be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be understood in a similar manner (e.g., "between," "directly between," "near," versus "directly near," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed terms.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. As used herein, terms such as "first," "second," and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as "inner," "outer," "lower," "below," "lower," "above," "upper," and the like, may be used herein to facilitate description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" may include both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Referring to fig. 1 and 2, a diaphragm valve 20 is shown installed in a manifold 22. The diaphragm valve 20 includes a valve body cylinder 24 and an electromagnet 26 coaxially aligned with respect to a longitudinal axis 28. The valve body cartridge 24 extends longitudinally between a mouthpiece end 30 and a diaphragm receiving end 32. The electromagnet 26 extends longitudinally between an armature receiving end 34 and a pole piece receiving end 36. It should be understood that the terms "longitudinal," "longitudinally," "axial," and "axially" as used herein refer to along longitudinal axis 28 or parallel to longitudinal axis 28. The diaphragm receiving end 32 of the valve body cartridge 24 and the armature receiving end 34 of the electromagnet 26 are releasably connected by a threaded connection 38. Manifold 22 includes a manifold bore 40. The valve body cartridge 24 is slidably inserted into the manifold bore 40 of the manifold 22. One or more sealing members 42, such as O-rings, are disposed in one or more annular grooves 44 formed in the valve body cartridge 24 and the electromagnet 26. The sealing member 42 abuts the manifold hole 40 to form a fluid seal.

The electromagnet 26 includes a first collar 46a and a second collar 46b that extend radially outward from the longitudinal axis 28. The electromagnet 26 also includes external threads 50 that engage with the manifold hole 40 to secure the diaphragm valve 20 to the manifold 22. The manifold 22 includes passageways 52a, 52b disposed in fluid communication with the manifold bore 40. In operation, the diaphragm valve 20 controls the flow of fluid, such as compressed air, between the passages 52a, 52b of the manifold 22.

With additional reference to fig. 3 and 4, the coil 54 and pole piece 56 are located in the electromagnet 26. A bobbin 58 is also provided in the electromagnet 26, supporting the coil 54. An armature 62 is slidably disposed in the electromagnet 26 for movement along the longitudinal axis 28 between a non-energized position (fig. 3) and an energized position (fig. 4). At least a portion of the pole piece 56 and at least a portion of the armature 62 are slidably received in the bobbin 58. The pole piece 56 may include a pressure balancing channel 64 extending through the pole piece 56 along the longitudinal axis 28. The pole piece 56 may also include a threaded end portion 66 that engages internal threads 68 in the pole piece receiving end 36 of the electromagnet 26. Thus, the axial position of the pole piece 56 may be adjusted along the longitudinal axis 28 by rotating the pole piece 56 relative to the electromagnet.

The pole piece 56 is disposed within a pole piece sleeve 70. The pole piece sleeve 70 includes a pole piece sleeve wall 72 and a pole piece sleeve flange 74. The pole piece sleeve wall 72 is located radially between the bobbin 58 and at least a portion of the pole piece 56. A pole piece sleeve flange 74 extends radially outward from the pole piece sleeve wall 72 toward the electromagnet 26. The pole piece sleeve wall 72 maintains the pole piece 56 in coaxial alignment with the bobbin 58, coil 54, and electromagnet 26 as the axial position of the pole piece 56 is adjusted along the longitudinal axis 28 by rotating the pole piece 56 relative to the electromagnet.

The electric shield 76 is releasably connected to the pole piece receiving end 36 of the electromagnet 26 by a threaded connection 78. The electrical enclosure 76 includes a plurality of electrical contacts 80 on a Printed Circuit Board (PCB)82 that are electrically connected to the coil 54. The electrical contacts 80 are configured to mate with an electrical connector 84 connected to one or more wire leads 86, the electrical connector 84 providing power to the diaphragm valve 20. Optionally, the electrical enclosure 76 may house a connector seal 88 disposed between the electrical connector 84 and the electrical enclosure 76. Diaphragm valve 20 can also include an electrical insulator 90 disposed between pole piece 56 and printed circuit board 82.

As shown in fig. 3, when the armature 62 is in the de-energized position, there is a gap 92 between the pole piece 56 and the armature 62. The armature 62 is slidably disposed within an armature sleeve 94 in the armature receiving end 34 of the electromagnet 26. The armature sleeve 94 includes an armature sleeve wall 96 and an armature sleeve flange 98. The armature sleeve wall 96 is located radially between the bobbin 58 and at least a portion of the armature 62. An armature sleeve flange 98 extends radially outwardly from the armature sleeve wall 96 toward the electromagnet 26. The armature sleeve wall 96 maintains the armature 62 in coaxial alignment with the bobbin 58, coil 54, and electromagnet 26 during sliding displacement of the armature 62 between the energized and non-energized positions. The armature sleeve wall 96 may be integrally connected to the armature sleeve flange 98, although other configurations are possible. The armature 62 may optionally include one or more depressions 100 for holding the armature 62 when assembling the diaphragm valve 20.

A biasing member 102, such as a helical metal compression spring, is located about the armature 62. The armature 62 includes a biasing member seat 104 that extends radially outward toward the electromagnet 26. The biasing member 102 has a first biasing member end 106 that contacts a biasing member seat 104 of the armature 62 and a second biasing member end 108 that contacts the armature sleeve flange 98. The biasing member 102 applies a biasing force 110 to the armature 62, biasing the armature 62 to the de-energized position (fig. 3).

As shown in fig. 4, when power is applied to the coil 54, the coil 54 generates a magnetic field that causes the armature 62 to be magnetically attracted toward the pole piece 56. The magnetic field exerts a magnetic force 112 on the armature 62, overcoming the biasing force 110 of the biasing member 102, moving the armature 62 to the energized position (fig. 4). The armature 62 will remain in the energized position for as long as power is supplied to the coil 54.

The diaphragm valve 20 includes a valve member 114 disposed in the valve body cartridge 24. The armature 62 includes a connection portion 116, and the valve member 114 is connected to the connection portion 116 of the armature 62 by a threaded connection 118. Thus, the valve member 114 slides within the valve body barrel 24 as the armature 62 moves between the energized and de-energized positions.

The diaphragm 120 is received in the diaphragm receiving end 32 of the valve body cartridge 24 between the connection portion 116 of the armature 62 and the valve member 114. More specifically, a threaded connection 118 between the armature 62 and the valve member 114 allows a diaphragm 120 to be clamped between the connection portion 116 of the armature 62 and the valve member 114. The diaphragm 120 provides an atmospheric seal for the diaphragm valve 20 to prevent fluid, such as compressed air, and contaminants from entering the electromagnet 26. When the armature 62 is in the de-energized position (fig. 3), the diaphragm 120 extends radially inward from the valve body cartridge 24 at a diaphragm plane 122, the diaphragm plane 122 being transverse to the longitudinal axis 28. This means that the diaphragm 120 is substantially flat and does not have one or more corrugated portions with a U-shaped cross-section. When the armature 62 moves to the energized position (fig. 4), the diaphragm 120 is offset from the diaphragm plane 122. The diaphragm 120 may be made of rubber, although various configurations and structural materials are possible.

Interface end 30 of valve body cartridge 24 includes at least one inlet port 124 and one outlet port 126. As shown in fig. 1, when the valve body cartridge 24 is installed in the manifold bore 40, the inlet port 124 and the outlet port 126 are positioned in fluid communication with the passages 52a, 52b of the manifold 22. A valve seat 128 is located between the inlet port 124 and the outlet port 126. The valve seat 128 may be integrally formed with the valve body cartridge 24 or may be a separate component made of a softer material such as rubber. Valve member 114 includes a seat engagement surface 130 that contacts seat 128 in a valve closed position (fig. 3) and moves away from seat 128 in a valve open position (fig. 4).

Valve body cartridge 24 also includes a piston bore 132. The valve member 114 has a piston 134, the piston 134 being received in the piston bore 132 and configured to slide within the piston bore 132 as the valve member 114 moves between the valve open position and the valve closed position. Alternatively, the diaphragm valve 20 may be configured as a pressure balanced valve. The inlet port 124 has a cross-sectional area. With the diaphragm valve 20 having a pressure balanced configuration, the piston 134 has a piston surface area equal to the cross-sectional area of the inlet port 124.

In the valve closed position shown in fig. 3, the biasing force 110 of the biasing member 102 urges the armature 62 to the de-energized position, and the valve member 114 moves in a valve closing direction 136. The valve seat engagement surface 130 of the valve member 114 is held in contact with the valve seat 128 by the biasing force 110 of the biasing member 102. Thus, when the diaphragm valve is de-energized, the diaphragm valve 20 prevents fluid flow between the inlet port 124 and the outlet port 126. In the valve open position shown in FIG. 4, when coil 54 is energized, magnetic force 112 acting on pole piece 56 overcomes biasing force 110 of biasing member 102, pulling armature 62 to the energized position and valve member 114 moves in valve opening direction 138. The valve seat engagement surface 130 of the valve member 114 moves away from the valve seat 128, thereby providing a flow path 140 from the inlet port 124 to the outlet port 126 when the diaphragm valve 20 is energized.

The armature receiving end 34 of the electromagnet 26 includes an armature cavity 142. A diaphragm support sleeve 144 is disposed in the armature cavity 142. The diaphragm support sleeve 144 has a support sleeve wall 146 and a support sleeve flange 148. The support sleeve wall 146 extends along the longitudinal axis 28, is generally cylindrical, and is coaxially aligned with the longitudinal axis 28. The support sleeve wall 146 extends annularly about the armature 62 and is spaced from the armature 62 to define a sleeve cavity 150 therein. The sleeve cavity 150 receives at least a portion of the armature 62. The biasing member 102 is located in the sleeve cavity 150 radially between the armature 62 and the support sleeve wall 146. The support sleeve flange 148 extends radially inward from the support sleeve wall 146 and is transverse to the longitudinal axis 28. More specifically, the support sleeve flange 148 extends radially inward of the biasing member seat 104 of the armature 62, while the connection portion 116 of the armature 62 is located radially inward of the support sleeve flange 148. The support sleeve flange 148 abuts and supports at least a portion of the diaphragm 120.

A spacer seal 152 is located between and in contact with the support sleeve wall 146 and the armature sleeve flange 98. The spacer seal 152 accommodates tolerance variations between the diaphragm support sleeve 144 and the armature sleeve 94. The diaphragm support sleeve 144 is threadably engaged with the valve body cartridge 24. Specifically, diaphragm support sleeve 144 includes a threaded shoulder 154 extending radially outward from support sleeve wall 146, and valve body cartridge 24 includes internal threads 156, which internal threads 156 engage threaded shoulder 154 of diaphragm support sleeve 144.

The diaphragm 120 may optionally include a peripheral lip 158. The peripheral lip 158 is received between the valve body cartridge 24 and the diaphragm support sleeve 144 to secure the diaphragm 120 within the diaphragm valve 20. In the example shown, the peripheral lip 158 of the diaphragm 120 has a ramp-shaped cross-section; however, other shapes may be used.

According to several embodiments, the valve body cartridge 24 is made of a polymeric material and is releasably threaded to the electromagnet 26. Polymeric materials are used for the valve body cartridge 24 for a variety of reasons, including: reducing the cost and weight of the diaphragm valve 20; allows the complex geometry of the valve body cartridge 24 to be more easily manufactured using a molding operation; reducing or eliminating corrosion of the valve body cartridge 24 in the installed position in the manifold 22; and to eliminate any influence of the magnetic field on the valve body cartridge 24 during operation of the coil 54. According to another embodiment, the valve body cylinder 24 is made of metal.

The foregoing description of the embodiments has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. These elements or features may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.

Claims (20)

1. A diaphragm valve, comprising:

an electromagnet having a coil and a pole piece therein;

a valve body cylinder connected to the electromagnet;

an armature slidably disposed in the electromagnet for movement along a longitudinal axis between an energized position and a de-energized position;

a valve member slidably disposed in the valve body barrel, the valve member being connected to and movable with the armature;

a biasing member disposed in the electromagnet for biasing the armature toward a de-energized position;

a diaphragm extending inwardly from the valve body barrel, received between the armature and the valve member, such that the diaphragm deflects as the armature and the valve member move along the longitudinal axis; and

a diaphragm support sleeve having a support sleeve wall defining a sleeve cavity and a support sleeve flange extending inwardly and transverse to the support sleeve wall, wherein the sleeve cavity receives at least a portion of the armature, and wherein the support sleeve flange abuts and supports at least a portion of the diaphragm.

2. The diaphragm valve of claim 1, wherein the biasing member is located in the sleeve cavity of the diaphragm support sleeve between the armature and the support sleeve wall.

3. The diaphragm valve of claim 2, wherein the armature includes a biasing member seat extending outwardly toward the support sleeve wall, and the biasing member has a first biasing member end contacting the biasing member seat of the armature.

4. The diaphragm valve of claim 3, further comprising:

a bobbin disposed in the electromagnet, the bobbin supporting the coil, at least a portion of the pole piece and at least a portion of the armature slidably received in the bobbin; and

an armature sleeve including an armature sleeve wall disposed between the bobbin and at least a portion of the armature and an armature sleeve flange extending outwardly from the armature sleeve wall toward the electromagnet, and the biasing member including a second biasing member end contacting the armature sleeve flange.

5. The diaphragm valve of claim 4, further comprising:

a spacer seal between and in contact with the support sleeve wall and the armature sleeve flange.

6. The diaphragm valve of claim 1, wherein the diaphragm includes a peripheral lip received between the valve body cartridge and the diaphragm support sleeve for protecting the diaphragm in the diaphragm valve.

7. The diaphragm valve of claim 6, wherein the peripheral lip of the diaphragm has a ramp-shaped cross-section.

8. The diaphragm valve of claim 1, wherein the valve body cartridge includes at least an inlet port, an outlet port, and a valve seat between the inlet port and the outlet port, wherein the valve member includes a seat engagement surface that contacts the valve seat in a valve closed position and moves away from the valve seat in a valve open position.

9. The diaphragm valve of claim 8, wherein the valve body cartridge comprises a piston bore and the valve member comprises a piston slidably received in the piston bore, wherein the inlet port has a cross-sectional area and the piston has a piston surface area equal to the cross-sectional area of the inlet port to create a pressure balanced condition.

10. The diaphragm valve of claim 1, wherein the diaphragm support sleeve is in threaded engagement with the valve body barrel.

11. The diaphragm valve of claim 1, wherein the diaphragm extends along a diaphragm plane transverse to the longitudinal axis when the armature is in one of the energized or de-energized positions.

12. The diaphragm valve of claim 1, further comprising:

a threaded connection between the armature and the valve member that allows the diaphragm to be clamped between the armature and the valve member.

13. The diaphragm valve of claim 1, wherein the pole piece includes a threaded end that engages with internal threads of the electromagnet and allows the axial position of the pole piece to be selected by rotating the pole piece relative to the electromagnet.

14. A diaphragm valve, comprising:

an electromagnet having a coil and a pole piece therein;

a valve body cylinder connected to the electromagnet;

an armature slidably disposed in the electromagnet for movement along a longitudinal axis between an energized position and a de-energized position;

a valve member slidably disposed in the valve body barrel, the valve member being connected to and movable with the armature;

a biasing member extending around the armature, the biasing member biasing the armature toward a de-energized position;

a diaphragm extending radially inwardly from the valve body barrel, received between the armature and the valve member; and

a diaphragm support sleeve having a support sleeve wall extending annularly about the biasing member and a support sleeve flange extending radially inward from the support sleeve wall such that the support sleeve flange abuts and supports at least a portion of the diaphragm.

15. The diaphragm valve of claim 14, wherein the armature includes a biasing member seat extending radially outward toward the support sleeve wall, and the biasing member has a first biasing member end contacting the biasing member of the armature.

16. The diaphragm valve of claim 15, further comprising:

a bobbin disposed in the electromagnet, the bobbin supporting the coil, the bobbin extending annularly around at least a portion of the pole piece and at least a portion of the armature; and

an armature bushing including an armature bushing wall disposed radially between the bobbin and at least a portion of the armature and an armature bushing flange extending radially outward from the armature bushing wall toward the electromagnet, and the biasing member including a second biasing member end contacting the armature bushing flange.

17. The diaphragm valve of claim 16, further comprising:

a spacer seal between and in contact with the support sleeve wall and the armature sleeve flange accommodates tolerance variations between the diaphragm support sleeve and the armature sleeve.

18. The diaphragm valve of claim 15, wherein the support sleeve flange extends radially inward from the biasing member seat of the armature.

19. The diaphragm valve of claim 15, wherein the diaphragm support sleeve includes a threaded shoulder extending radially outward from the support sleeve wall, and wherein the valve body barrel includes internal threads that engage the threaded shoulder of the diaphragm support sleeve.

20. A diaphragm valve, comprising:

a manifold including a manifold hole;

a valve body cylinder accommodated in the manifold hole;

an electromagnet connected to the valve body barrel; the electromagnet has a coil and a pole piece, the coil and the pole piece being located in the electromagnet;

an armature slidably disposed in the electromagnet for movement along a longitudinal axis between an energized position and a de-energized position;

a valve member slidably disposed in the valve body barrel, the valve member being connected to and movable with the armature;

a biasing member disposed in the electromagnet, the biasing member biasing the armature toward a de-energized position;

a diaphragm extending inwardly from the valve body barrel, received between the armature and the valve member, such that the diaphragm deflects as the armature and the valve member move along the longitudinal axis; and

a diaphragm support sleeve having a longitudinally extending support sleeve wall defining a sleeve cavity and a support sleeve flange extending inwardly from the longitudinally extending support sleeve wall, wherein the sleeve cavity receives at least a portion of the armature and the transverse support sleeve flange abuts and supports at least a portion of the diaphragm.