FLAPPER CHECK VALVE

Abstract

A check valve includes a housing defining a pair of valve openings, a pair of flappers pivotably mounted to a pin and such that they are configured to rotate relative to the housing between an open position in which they permit fluid flow through the valve openings and a closed position in which they prevent fluid flow through the valve openings, and an element configured to stop and hold the flappers in the open position. A cavity is formed between the pair of flappers and stop element when the flappers are in the open position. Each of the flappers comprise one or more contact surfaces configured to contact the stop element when in the open position. The stop element has stop surfaces with stationary contact areas configured to oppose and abut the flapper contact surfaces when the flappers are in the open position.

Claims

1. A check valve comprising: a housing defining a pair of valve openings; a pair of flappers pivotably mounted to a pin and such that they are configured to rotate relative to the housing between an open position in which they permit fluid flow through the valve openings and a closed position in which they prevent fluid flow through the valve openings; and an element configured to stop and hold the flappers in the open position; wherein each of the flappers comprise one or more surfaces configured to engage and contact static, opposing portions of the stop element and such that one or more openings are formed between the pair of flappers and each stop element when the flappers contact the stop element in the open position to ensure fluid is able to flow therebetween.

2. A check valve as claimed in claim 1, wherein: the opposing portions of the stop element each comprise a pair of stop surfaces, the stop surfaces comprising respective contact areas configured to oppose and abut the contact surfaces of the flappers when the flappers contact the stop element in the open position; at least one of the contact surfaces of the flappers and contact areas of the stop element are formed on one or more bumpers disposed on a respective one of the flappers and/or stop surfaces; the one or more openings are formed between each of the flappers and the stop element adjacent to the one or more bumpers when the flappers contact the stop element in the open position; and each of the contact areas of the stop elements are configured to be conformal to the contact surface of a respective flapper when the flappers contact the stop element in the open position.

3. A check valve as claimed in claim 2, wherein the pair of valve openings define a plane, and wherein the stop element comprises a strip of material oriented parallel to the plane, wherein the strip of material is substantially flat and comprises a thickness selected such that a superficial contact width (W) between the contact surfaces of the flappers and contact areas of the stop elements is equivalent.

4. A check valve as claimed in claim 1, wherein the contact surfaces of the flappers and opposing portions of the stop element are planar.

5. A check valve as claimed in claim 1, wherein the static, opposing portions of the stop element define planar surfaces that converge towards each other in the direction of the valve openings.

6. A check valve as claimed in claim 1, wherein the stop element comprises one or more apertures.

7. A check valve as claimed in claim 2, wherein the one or more bumpers are configured to: distribute stress around the flappers; and/or distribute stress along the pin.

8. A check valve as claimed in claim 1, wherein each of the flappers comprise two or more knuckles configured to contact the pin, and wherein at least one of the contact surfaces is aligned to one of said knuckles.

9. A check valve as claimed in claim 1, wherein the flappers are asymmetric relative to the pin such that, when in the open position, openings of one of the flappers are offset from any openings of the other of the flappers.

10. A check valve as claimed in claim 1, further comprising a pair of mounting posts for supporting the pin and the stop element, wherein the mounting posts and the stop element are formed of a single strip of material.

11. A check valve as claimed in claim 1, wherein each flapper comprises a length (L) along which the contact surfaces extend substantially parallel to the pin, the contact surfaces extending across at least 20% of the length (L).

12. A check valve comprising: a housing defining a pair of valve openings; a pair of flappers pivotably mounted to a pin such that they are configured to rotate relative to the housing between an open position in which they permit fluid flow through the valve openings and a closed position in which they prevent fluid flow through the valve openings; a pair of mounting posts for supporting the pin; and an element configured to stop and hold the flappers in the open position, wherein the mounting posts and stop element are formed from a single strip of material.

13. A check valve as claimed in claim 12, wherein: each of the flappers comprise one or more contact surfaces configured to contact the stop element when in the open position; the stop element comprises a pair of stop surfaces, comprising respective contact areas configured to oppose and abut the contact surfaces of the flappers when the flappers are in the open position, said contact areas configured to remain stationary; and at least one of the contact surfaces of the flappers and contact areas are formed on one or more bumpers disposed on a respective at least one of the flappers and stop surfaces.

14. A check valve as claimed in claim 13, wherein the contact areas are configured to be conformal to the contact surfaces of the flappers when the flappers are in the open position.

15. A method of manufacturing the stop element of claim 1, the method comprising: forming the stop element and a pair of mounting posts from a single flat piece of metal; and selecting a thickness of the flat piece of metal such that a superficial contact width (W) between contact surfaces of the flappers and contact areas is equivalent.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings in which:

[0034] FIG. 1A shows a cross section of a known check valve in its open position, the check valve comprising pair of flappers, a stop pin and a hinge pin.

[0035] FIG. 1B shows regions of wear on the flapper and stop pin of the check valve of FIG. 1A.

[0036] FIG. 1C shows the wear pattern of the hinge pin of the check valve of FIG. 1A after use.

[0037] FIG. 2 shows a check valve in accordance with an embodiment of the invention wherein a flapper is in the open position, and another flapper is in the closed position.

[0038] FIG. 3 shows a cross section of the check valve of FIG. 2.

[0039] FIG. 4 shows a cross section of the check valve of FIG. 2 in the open position.

[0040] FIG. 5 shows a plan view of the check valve of FIG. 2 in the closed position.

[0041] FIG. 6 shows a check valve in accordance with another embodiment of the invention.

DETAILED DESCRIPTION

[0042] With reference to FIGS. 2-6, various embodiments of a check valve 20 in accordance with this disclosure are herewith described.

[0043] The check valve 20 comprises a housing 22. The valve housing 22 is a generally planar annular element which may be mounted in a pipe, duct or the like. The valve housing 22 comprises a pair of generally D-shaped valve openings 24 which are separated by a central web 26 of the valve housing 22.

[0044] A pair of mounting posts 40 extend upwardly from the valve housing 22. The mounting posts 40 may be integrally formed in place, for example cast, with the valve housing 22. Alternatively, the mounting posts 40 may be separately formed from the valve housing 22 and mounted thereto by suitable means, for example, welded thereto, or attached by bolts or other fasteners (not shown).

[0045] A pin 28 is mounted between the mounting posts 40 above the central web 26. The pin 28 may be a unitary structure, or may be constituted from two or more sections. The pin 28 may be mounted through pin apertures 48 in the mounting posts 40. Thus, the pin 28 may be installed in sections between mounting posts 40 already in place, or a unitary pin 28 may be installed, e.g., from one side through apertures 48 in the side of the posts. Alternatively, a pin 28 (e.g. a unitary pin) may be installed between the mounting posts before they are in place (i.e. before their mounting to the housing 22 as discussed below).

[0046] A stop element 42 (e.g. a rigid stop element) abridges the mounting posts 40, and is positioned above the pin 28.

[0047] A pair of generally D-shaped flappers 30 are pivotally mounted to the pin 28 and each flapper 30 interacts with a respective valve opening 24 to selectively close it. As is known in the art, the flappers 30 are pivotally mounted to the pin 28 by a hinge mechanism including respective mounting lugs or knuckles 29, and are pivotable between an open position and a closed position. In the closed position they close the valve openings 24, thereby preventing flow through the check valve, and in the open position the flappers 30 permit fluid to pass through the valve openings 24 in a flow direction 100 from a pressure side 110 of the valve 20 to a suction side 120 of the valve 20.

[0048] FIGS. 2 and 3 show a check valve 20 wherein, for illustrative purposes to show both positions, one of the flappers 30a is disposed in the closed position, whilst the other flapper 30b is disposed in the open position. In the open position the flappers 30 engage the stop element 42 and define an opening angle α.

[0049] In normal operation, and when a pressure difference exists between the pressure side 110 and the suction side 120, a fluid exerts a force F on the flappers 30. This serves to move the flappers 30 from the closed position to the open position when the pressure difference exceeds a threshold pressure. The force is generally exerted on a flapper surface 36 (e.g. the pressure side surface). Thus, the magnitude of the force F on the flapper is reduced as the opening angle α is increased and the direction of fluid flow becomes more perpendicular to the surface 36.

[0050] In this context, and contrary to established principles for ensuring a maximised opening 24 area for maximised fluid flow 100, it has been found that a smaller opening angle α may reduce fluttering. This is because a larger force F is maintained against the flapper surface 36, relative to a smaller force which is present when a large opening angle α is employed.

[0051] However, maintaining a larger force F can also increase stress and associated wear (e.g., the wear down 16 of either or both of the flapper 2 surface or cylindrical surface of the stop pin 10 illustrated in FIG. 1B). Consequently, reducing fluttering in this way may lead to unintended knock-on effects which reduce the lifetime of the valve.

[0052] Advantageously, it has been found that a relatively large contact surface area 34, 44a between the flappers 30 and the stop element 42 may help to more evenly distribute stress across the flapper 30 and reduce wear on both the flapper 30 and the stop element 42. The even distribution of stresses and the reduction of wear of the flapper 30 and stop element 42 can also subsequently result in reduced stress and wear on the pin 28. It has therefore been found to be desirable to maximise the surface area of the contact surfaces between the flapper and stop element.

[0053] In accordance with embodiments, and with continued reference to FIGS. 2-4, the stop element 42 is shaped so as to present a surface 44 which is complementary or conformal to the flappers 30 in their open position. In embodiments the stop element 42 comprises a contact surface or area 44a which is conformal to the contact surface 34 of the respective flappers 30. For example, both the contact areas 44a on the stop element 42, and contact surfaces 34 on the flapper 30 may be flat (in contrast, for example, to established flat flapper and round stop pin arrangements). Either or both respective contact surfaces or areas 34, 44a may also be angled (e.g. inclined such that they are not parallel or perpendicular to a major surface thereof) in order to be complimentary to the angle of the other respective contact surface or area 34, 44a when the valve 20 is in the open position. In this way, the contact surface area between the flappers 30 and stop element 42 may be maximised.

[0054] With reference to FIG. 4, it has also been found that, during operation, a portion of fluid 200 may pass through the hinge mechanism (e.g. through gaps in the knuckles 29) and enter a cavity 50 formed between the flappers 30 and stop element 42 when in the open position. A build of pressure P resulting from this passage of fluid may oppose the force F from the fluid flow 100 and push the flappers 30 towards the closed position to allow the pressure build up to escape, thereby causing the flappers 30 to flutter.

[0055] Such fluttering can be present even in the absence of this passage of fluid (for example, when the hinge mechanism is sealed to prevent the passage of fluid to the cavity). With reference to FIG. 1A, it is believed that a high pressure fluid flow 100 through the valve opening 4 can cause local pressure fluctuations on the exposed surface of the flapper (e.g. the pressure side surface) which leads to the fluttering. Further, the fluid flow 100 over the tips of the flappers 2 can create eddies (turbulence) in the vacant space behind the flappers 2 (e.g. on the suction side) which, again, results in the fluttering of the flappers 2.

[0056] It has been found to be highly beneficial to provide clearances or openings 38 between the flappers 30 and the stop element 42 (when the flappers 30 are in the closed position), to not only allow the escape of fluid in the cavity 50, but to facilitate a fluid flow 300 therethrough such that the formation of eddies are prevented, thereby ensuring lower stress laminar flow regimes (see FIG. 4).

[0057] There are therefore potentially conflicting requirements for maximising the contact area 34 between the flappers 30 and stop element 42 whilst simultaneously facilitating a flow of fluid between the flappers 30 and stop element 42.

[0058] In accordance with embodiments, and with reference to FIG. 5, it has been found beneficial to create a contact area 34 between each flapper 30 and the stop element 42 which extends across at least 20% of the length L of the flapper 30 (e.g. the superficial length L which would be in contact with the stop element 42 in the absence of any further surface features), whilst at the same time providing openings 38, clearances or vacancies along the same length L. The contact area between each flapper 30 and the stop element 42 may extend also across at least 40% of the length L of the flapper 30.

[0059] The contact area between flappers 30 and stop element 42 may be facilitated by one or more bumpers 32 (e.g. non-resilient or rigid bumpers which are substantially solid, hard, made of non-resilient materials and/or devoid of cushioning or resilient features, etc.) provided on either or both of the flappers 30 (see FIGS. 2-6). Additionally or alternatively, such bumpers may be provided on the stop element, e.g. on opposing lateral stop surfaces 44 thereof (not shown), such that the contact areas 44a of the stop element 42 are provided on the bumpers. The bumpers 32 may extend over a length L of the flapper (or a length of the stop element). In embodiments, the bumpers may cumulatively extend across at least 20% of the length L of the flapper 30 or across at least 40% of the length L of the flapper 30 or stop element 42.

[0060] In cases where bumpers are employed, the openings 38 may be provided between or adjacent to the bumpers 32. In these embodiments a height of the bumpers may be regulated so as to control the size of the openings 38.

[0061] Further, to ensure a maximised contact area (and optimise the weight of the check valve 20, as discussed below), a width W of each of the bumpers 32 may be controlled so as to match (and, thus, be complimentary to) a superficial contact width W of the stop element 42 (see FIGS. 3 and 5).

[0062] With a view to further facilitating flow through the cavity 50, and in accordance with some embodiments, the stop element 42 itself may comprise openings or apertures 46 configured to allow the passage of air from the cavity 50 (see FIG. 6). Such apertures 46 may be provided in addition to, or as an alternative to, the previously described openings 38 between flapper and stop element.

[0063] In order to harmonise fluid flow through the cavity, it has been found to be beneficial to offset the bumpers 32 on one flapper 30 from the bumpers 32 on the other flapper 30. Accordingly, in embodiments, the bumpers 32 of the respective flappers are positioned asymmetrically to each other with respect to (on either side of) the centrally positioned pin 28 of the hinge mechanism.

[0064] With a view to more evenly distributing stresses along the pin 28, it has also been found to be beneficial to substantially align one or more of the bumpers 32 with the knuckles 29. Accordingly, in some embodiments, at least one bumper 32 of the one or more bumpers 32 on each flapper 30 is aligned with one of the knuckles 29 (i.e. aligned with respect to pin 28).

[0065] As discussed above, the opening angle α impacts the force F exerted on the flappers 30 in the open position. With a view to ensuring a more stable operation (e.g. to prevent fluttering and the associated wear), it is advantageous to limit the opening angle α in order to maintain a higher force F for steadily holding the flappers in the open position. For example, in some embodiments the opening angle α between the flappers 30 and the openings 24 may be less than 80 degrees. Limiting the opening angle may be achieved by providing a stop element with a larger separation between its sides.

[0066] However, the provision of ever larger stop pins (in the established cylindrical form) can exponentially increase the weight of the check valve as a whole. Such an increase in weight is highly undesirable, particularly in applications within the field of aerospace.

[0067] Thus, in embodiments, the stop element 42 is advantageously not cylindrical, or not substantially cylindrical in form. Instead the stop element 42 is provided as (comprises or consists of) a substantially flat, e.g. bar-shaped, strip of material. For example, the stop element 42 may comprise a rectangular, or trapezoid cross-section as it extends from one mounting post 40 to the other. In this form the breadth of the stop element 42 (i.e. the separation between opposing lateral sides 44 or contact areas 44a thereof) may be easily controlled without substantially affecting the overall mass of the check valve 20. Thus, the opening angle α of the check valve 20 may be optimised without adversely affecting the weight. The provision of the flat shape also allows thickness thereof to be more easily tailored. For example, the thickness of the stop element may be provided to as to exactly match a superficial contact thickness or width W of the bumpers 32. In this way the mass of the check valve may be minimised, and indeed reduced below current standards. Apertures 46, where provided, are easier to install and tailor as well.

[0068] Further, in embodiments, the stop element 42 is a non-resilient or rigid stop element 42 (i.e. substantially solid, hard, made of non-resilient materials and/or devoid of cushioning or resilient features, etc.). As such, the contact areas 44a of the stop element 42 may be configured to remain stationary, even when subject to the opening and closing or percussion of the flappers 30. Advantageously, the absence of any resilient or cushioning features (i.e. the provision of stationary stop contact surfaces or areas) helps to prevent vibratory movements in the flappers 30, thereby preventing increased wear on the pin of the hinge mechanism (see, for example, FIG. 1C).

[0069] The stop element 42 and the mounting posts 40 may also form a unitary or continuous bridge structure extending from one side of the housing 22 to the other (e.g. a single and/or continuous strip of material). In such embodiments the bridge structure may simultaneously perform the functions of supporting the pin 28, supporting the stop element 42 and serving as the stop element 42. The bridge structure may advantageously comprise a substantially uniform thickness along its entire build (i.e. the mounting posts 40, stop element 42 and any intervening sections may be substantially the same thickness and/or have substantially the same cross-section). The bridge structure may be formed of a single, bent piece of material of uniform thickness (e.g. sheet metal) which is shaped to form the mounting posts 40, the stop element 42, and/or pin apertures 48 for supporting the pin 28. Alternatively, the bridge structure may be cast, either independently, or integrally to the housing 22. In cases of bridge structure being formed separate from the housing, the bridge structure may be deformed along its axis to facilitate installation of the pin 28 (e.g. a unitary hinge pin) between the mounting posts 40. The bridge structure and pin may then be mounted to the housing 22 by the mounting posts 40 thereof by any suitable means (as discussed above).

[0070] Regardless of how the bridge structure is formed (e.g. from a sheet of metal, or by casting, separately or as part of the housing 22), the simplified design thereof (e.g. its substantially uniform thickness and/or its continuous design) may significantly improve the ease of its manufacture (e.g. by being stamped from sheet metal, or by greatly reducing the complexity of a mould needed for casting).

[0071] Although the present disclosure has been described with reference to various embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the scope of the invention as set forth in the accompanying claims.