Protection structure for gas cylinder and valve replacement

Abstract

There is provided a protection structure for a gas cylinder assembly comprising a gas cylinder body and a valve. The gas cylinder body includes a base and a neck to which a proximal end of the valve is connectable in use. The protection structure comprises first and second structural sections, the first section being connectable to the valve such that the second section is spaced from the valve by the first section. Further, in use, the second section is arranged to transfer impact forces to the first section, and the second section is arranged to deform with respect to the second section in response to said impact forces to reduce the peak impact force on the valve.

Claims

1. A protection structure for a gas cylinder assembly comprising a gas cylinder body and a valve, the gas cylinder body including a base and a neck to which a proximal end of the valve is connected in use, the valve having a housing, an outlet, an integrated pressure regulator, a fill port, and a distal end remote from the gas cylinder body that forms a top surface of the gas cylinder assembly, the protection structure comprising: a first hollow section having a closed lower end connectable to the top surface of the gas cylinder assembly at the distal end of the valve and extending further distal from the cylinder body, the first hollow section having an open upper end; a second hollow section arranged in a stacked configuration on the first section such that the second section is further distal from the gas cylinder body than the first section and is spaced from the valve by the first section, the second hollow section having an open lower end connected directly to and in contact with the open upper end of the first hollow section and an upper open end distal from the first hollow section, wherein, in use, the second section is arranged to transfer impact forces to the first section, and the first section is arranged to deform with respect to the second section in response to said impact forces to reduce the peak impact force on the valve.

2. A protection structure according to claim 1, wherein first section comprises a tapered section.

3. A protection structure according to claim 1, wherein the second section is substantially cylindrical.

4. A protection structure according to claim 1, wherein the first and second sections are connected by mating flanges.

5. A protection structure according to claim 1, wherein at least one of the first and second sections is formed from mild steel.

6. A protection structure according to claim 1, wherein the second section is formed from a thicker or harder material than the first section.

7. A protection structure according to claim 6, wherein the second section is formed from thicker material than the first section, the material having a yield stress in the range of 100-250 MPa.

8. The protection structure of claim 1, further comprising a guard body that is arranged, in use, to surround the valve and protection structure, at least a portion of the guard body being supported by the protection structure.

9. A protection structure according to claim 8, wherein the guard body comprises first and second clamshell portions arranged to connect directly to the protection structure.

10. A protection structure according to claim 8, wherein the guard body is formed from a plastics material.

11. A valve assembly comprising a proximal end connectable to a gas cylinder and a distal end comprising a protection structure according to claim 1.

12. A valve assembly according to claim 11, wherein the protection structure is connected to the distal end of the valve assembly by removable or permanent fixings.

13. A gas cylinder assembly comprising a gas cylinder body and a valve assembly according to claim 11.

14. A valve assembly of claim 11, further comprising a guard body that is arranged, in use, to surround the valve and protection structure, at least a portion of the guard body being supported by the protection structure.

15. A valve assembly according to claim 14, wherein the guard body comprises first and second clamshell portions arranged to connect directly to the protection structure.

16. A gas cylinder assembly according to claim 13, wherein the valve assembly further comprises a guard body that is arranged, in use, to surround the valve and protection structure, at least a portion of the guard body being supported by the protection structure.

17. A gas cylinder assembly according to claim 16, wherein the guard body comprises first and second clamshell portions arranged to connect directly to the protection structure.

Description

(1) Embodiments of the present invention will now be described in detail with reference to the accompanying drawings, in which:

(2) FIG. 1 is a schematic diagram of a gas cylinder and valve assembly;

(3) FIG. 2 is a perspective view of a valve assembly and regulator suitable for use with aspects of the present invention;

(4) FIG. 3 is a perspective view of a protection structure according to an embodiment of the present invention;

(5) FIG. 4 is a cross section taken along a vertical plane through the protection structure of FIG. 3;

(6) FIG. 5 is a perspective view of the protection structure of FIGS. 3 and 4 connected to the valve of FIG. 2;

(7) FIG. 6 is a perspective view of protection structure and valve of FIG. 5 with the protection structure shown as transparent to reveal the fixing structure below;

(8) FIG. 7 is a cross section of a gas cylinder assembly incorporating the protection structure of FIGS. 3 to 6 taken along a vertical plane;

(9) FIG. 8 is a perspective view of a guard arrangement for use with the protection structure of FIGS. 3 to 7;

(10) FIG. 9 is an alternative perspective view of the guard arrangement shown in FIG. 8;

(11) FIG. 10 is a cross section similar to FIG. 7 but showing the guard arrangement of FIGS. 8 and 9 connected to the protection structure and gas cylinder shown in FIG. 7;

(12) FIG. 11 is a cutaway view showing a simulation of the effect of an impact on a protection structure, guard, valve and gas cylinder body; and

(13) FIG. 12 is a cutaway view similar to FIG. 11 showing a simulation of the effect of an impact on an alternative point of the protection structure, guard, valve and gas cylinder body.

(14) The present invention relates to an energy absorbing protection structure fitted to a valve of a gas cylinder package. The protection structure enables the management of the energy experienced by a cylinder package during an impact scenario. In the majority of applications the protection structure is designed to fit onto the cylinder valve and interface with the guard itself. If the package is then struck with significant force, such as falling off the back of a lorry, then the energy absorber acts to manage the both the maximum peak force seen in the valve and the amount of energy the valve is required to dissipate.

(15) FIG. 2 shows a perspective view of a valve 16 for use with the present invention. In this example, and in addition to the features described with reference to the example of FIG. 1, the valve 16 comprises an integrated pressure regulator 30 and a fill port 32 to enable filling of a gas cylinder. Non-exhaustive examples of suitable regulators may be single or double diaphragm regulators. However, the skilled person would be readily aware of variations that could be used with the present invention.

(16) The regulator 30 is operable to receive gas from the interior of the gas cylinder 12 at full cylinder pressure (e.g. 100 bar), but to deliver gas at a substantially constant fixed low pressure (e.g. 5 bar) to the outlet 24. This is achieved by a feedback mechanism whereby a poppet valve, operable to translate towards and away from a valve seat, is connected to a diaphragm. The pressure of gas downstream of the valve is operable to act on the diaphragm in opposition to the biasing force of a spring. A graspable handle (shown in FIGS. 7 and 10) is provided to enable a user to adjust the biasing force of the spring, thereby moving the position of the diaphragm and, as a result, adjusting the equilibrium spacing between the poppet valve and the valve seat. This enables adjustment of the dimensions of the aperture through which the high pressure gas flow from the outlet 24 can pass, and so allows the output pressure to be set.

(17) In this example, the outlet 24 comprises a quick connect orifice. An upper surface 34 of the valve 16 is arranged to receive the protection structure 100 of an embodiment of the invention as will be described later. The surface 34 of the valve 16 is arranged at a distal end of the valve 16 remote from the connection to the gas cylinder 14 and, when the valve 16 is attached to an upright gas cylinder, will form the top surface of the gas cylinder assembly 10. The surface 34 is substantially planar to enable elements to be fitted easily and securely.

(18) FIGS. 3 and 4 show a protection structure 100 according to an embodiment of the present invention. In FIGS. 3 and 4, the protection structure 100 is shown separate from the valve 16. The protection structure 100 comprises first and second sections 102, 104. The first section 102 comprises a base 106, a tapered cylindrical section 108 and a first flange 110. The base 106 is arranged to connect to the upper surface 34 of the valve 16 (as shown in FIGS. 5 to 7 and 10) in use as will be described later.

(19) The second section 104 comprises a cylindrical centre section 112 tapering outwards at either end to form second and third flanges 114, 116. The second section 104 is connected to the first section 102 by connection of the first and second flanges 110, 114. This may be achieved through numerous means. Mechanical fastenings such as bolts or screws or a bracket may be used. However, it is preferred that permanent attachment techniques are utilised to prevent variations in tolerances and to ensure durability of the protection structure 100. Such attachment techniques may include brazing, welding, rivoting, spacer welding or gluing.

(20) In one embodiment, the first and second sections 102, 104 of the protection structure 100 are formed from work hardened mild steel. The first and second sections 102, 104 are formed through stamping, pressing or spinning blank material to form the desired shape. Whilst work hardening can be achieved simply as a by-product the above manufacturing processes, the amount of hardening is not well defined and varies depending upon the process used.

(21) Therefore, to ensure consistency of material structure, annealing is carried out subsequent to formation of the first and second sections 102, 104 to manage further the material characteristics and prevent inadvertent local hardening of, for example, the second section 104 which may reduce the protection capabilities of the protection structure 100.

(22) However, other treatment processes or work hardening processes may be used. Further, whilst the present embodiment is described with reference to mild steel, the skilled person would readily be aware of other materials suitable for use with the present invention. When annealed, it is found that the mild steel used has a material yield stress in the range of 170-250 MPa. However, other materials in the range of 100-250 MPa may also be used, for example aluminium. The yield stress is required to fall within the specified range. If it is too hard or too soft, it will not provide the required protection.

(23) The first and second sections 102, 104 comprise mild steel of different thicknesses. From experimental data, the first section 102 has a thickness of 1.5 mm and a second section 104 has a thickness of 2.64 mm. These dimensions have been found to be optimal for protection of the valve of a 100 kg gas cylinder when the same material is used for both the first and second sections 102, 104. In other words, a thickness ratio of the first section to the second section in the range of 0.5-0.6 is considered desirable for the materials discussed above. However, other dimensions could be used with different materials and different material strengths.

(24) What is desirable is that the first section 102 is operable to deform under a lower load than the second section 102. This may be due to material, structural or geometric properties—for example, this may be due to the reduced strength or hardness of the material of the first section 102 relative to the second section 104. Whilst, in the present embodiment, this is achieved at least in part by provision of a thicker second section 104 when compared to the first section 102, the desired technical effect may be achieved in a different manner.

(25) For example, the second section 104 may have the same or similar material thickness to the first section 102 but be formed from a harder material or a material with a greater resistance to tensile stress. Further, different geometries and structures may be used for the first and second sections 102, 104 to provide the necessary utility. For example, a honeycomb or other reinforcing structure may be used for the second section 104 to provide enhanced rigidity over and above the first section 102.

(26) Nevertheless, the skilled person would be readily aware that, irrespective of the material and/or structural choice for the first and second sections 102, 104, the strength of the first section 102 is required to be selected such that the first section 102 collapses under a lower load than either the second section or the valve 16.

(27) FIGS. 5 to 7 show the protection structure 100 connected to the valve 16. FIGS. 5 and 6 show perspective views of the combined arrangement, with FIG. 6 showing the protection structure 100 as transparent to enable the fixing of the components to be shown. FIG. 7 shows a cross section through the arrangement.

(28) As shown, the protection structure 100 is attached to the upper surface 34 of the valve 16 such that the protection structure 100 extends upwardly above the valve 16 and forms the upper end of the gas cylinder assembly 10.

(29) In this embodiment, the first section 102 is connected to the cylinder valve 16 by means of mechanical fastenings such as bolts B. In FIGS. 6 and 7, it can be seen that the protection structure 100 is connected by three M6 bolts. In one embodiment, the protection structure 100 may be spaced from the cylinder valve 16 by washers or other suitable spacers through which the bolts or fasteners may extend.

(30) However, other connection means may be utilised. For example, other mechanical fastenings direct to the valve 16 may be used such as screws. Alternatively, a bracket arrangement may be used to enable ease of removability. As a further alternative, the protection structure 100 may be permanently attached to the valve 100 by welding, brazing or riveting.

(31) Additionally, it may be desirable in certain applications to space the protection structure 100 from the upper end 34 of the valve 16. This may be achieved through use of a washer or spacer between the valve 16 and the protection structure.

(32) In use, the protection structure 100 is arranged to reduce the impact on the cylinder valve 16 should the gas cylinder assembly 10 be dropped inadvertently and land on the valve structure 16, as will be described in detail later.

(33) Therefore, the protection structure 100 is designed to operate in two sections. The first section 102 is made from thinner mild steel than the second section 104. Thus, in response to an impact, the second section 104 is arranged to transfer impact forces through the first section 102. The first section 102 is, concomitantly, arranged to deform in response to the impact forces to absorb the peak impact force resulting from the impact. In other words, the first section 102 is arranged to function as a “crumple zone” between the second section 104 and the valve 16 to spread the impact force over a longer time period and, as a result, reduce the peak impact force on the valve 16.

(34) With reference to FIGS. 8 to 10, a guard arrangement 118 is provided. FIGS. 8 and 9 show perspective views of the guard 118 in an assembled form removed from the gas cylinder assembly 10. FIG. 10 shows a cross section through a gas cylinder assembly 10 with the guard arrangement 118 fitted in place.

(35) As shown in FIGS. 8 and 9, the guard 118 is formed in three components: first and second housings 120, 122 and a rotatable cap 124. The first and second housings 120, 122 are arranged to form a clamshell structure connected by the rotatable cap 124 at an upper end and by fixing means (such as screws) at a lower end.

(36) When assembled, the first and second housings 120, 122 and the rotatable cap 124 form the guard 118. The guard 118 is substantially elliptical and has a circular cross-section. Provision may be made within the structure of the guard 118 for one or more access ports (not shown). These access ports may include items such as a display, or provide access to the outlet 24, the fill port 32 or the graspable handle to enable operation and selection of gas dispensation modes or pressures.

(37) As shown in FIG. 10, the first and second housings 120, 122 are fitted on either side of the valve 16 and protection structure 100 such that they surround these components. With further reference to FIG. 10, the guard 118 is arranged to interface with the protection structure 100 at an upper end and the protection structure is arranged to support a portion of the guard 118.

(38) The guard arrangement 118 is arranged to surround the valve arrangement 16 and protection structure 100, and provides both structural and environmental protection for the valve 16 and related components. In other words, the guard 118 forms a housing or cover for the valve 16. Further, the guard 118 improves the aesthetic appearance of the cylinder assembly 10 and enables further items to be contained within; for example, an electronic display (arranged to fit in an aperture 120a formed in the first housing 120) or additional electronics or components required for operation of the gas cylinder assembly 10.

(39) Therefore, the guard 118 and protection structure 100 together form an enclosure and surround for the valve 16. However, in contrast to known arrangements, the permanent or semi-permanent attachment of the protection structure 100 to the valve 16 itself permits a greater flexibility in design freedom for the guard 118 whilst still providing the necessary structural rigidity to enable the guard 118 to be fitted to larger cylinders of the order of 100 kgs. In other words, the protection structure 100 forms an integrated part of the valve 16 arranged to connect the guard 118 to the valve 16 and which permits the guard 118 to be used with a wide range of cylinder sizes and weights.

(40) The rotatable cap 124 is connected by means of a push-fit connection to the top of the first and second housings 120, 122 to hold them in place at an upper end. The rotatable cap 124 is arranged to rotate about the longitudinal axis of the gas cylinder 12 and around the upper end of the guard 118 and protection structure 100 so that the cylinder assembly 10, when in an upright position, can be rolled by a user whilst the user holds the rotatable cap 124 with one hand. The fixing means are then used at a lower end of the guard 118 to secure the first and second housings 120, 122 to one another and to the valve 16.

(41) The first and second housings 120, 122 may be made from any suitable material. However, the choice of material is considerably wider than for conventional metallic or thick-plastic guards because the strength and structural integrity requirements of the guard 118 are lower due to the presence of the protection structure 100. Nevertheless, injection moulded plastics material is the preferred material choice due to the ease of manufacture and the range of design freedom. Plastics materials such as ABS or polycarbonate may be used in non-limiting and non-exhaustive examples.

(42) As shown in FIGS. 8 to 10, the guard 118 comprises a skirt 126 which depends from the lower portion of the guard 118 and extends around the base of the guard 118. The skirt 126 forms a dependent lip which is arranged to surround the neck of the gas cylinder 12 and has a curved cross-section when viewed in a vertical plane as shown in FIG. 10.

(43) In this embodiment, the skirt 126 is arranged to be graspable by personnel to facilitate lifting, handling and general manoeuvring of the gas cylinder assembly 10. Conventional gas cylinders are often provided with a handle at an upper end. However, such handles are often only suitable to be grasped by a single user. Given the weight of such cylinders, which may be in excess of 100 kgs, this is often impractical or unsafe. Further, the location of a handle relatively high (e.g. on the top of a cylinder as is known) presents difficulties for a user to attempt to lift the cylinder using such a handle.

(44) In contrast to known arrangements, the skirt 126 is arranged at a lower height (at approximately the neck 20 of the gas cylinder 12 when the valve 16 and guard 118 are installed on the gas cylinder body 14). Further, the skirt 126 extends around the entire circumference of the gas cylinder assembly 10. This permits two users to grasp a gas cylinder assembly 10 irrespective of the rotational orientation of the cylinder assembly 10. In other words, the location and arrangement of the skirt 126 permits straightforward lifting of the gas cylinder assembly 10 by two users stood either side of the gas cylinder assembly 10.

(45) As a yet further benefit, the skirt 126 is permanently attached to the gas cylinder 12 and does not require a separate lifting apparatus such as a removable lifting clamp. This aids in the convenience of manoeuvre of the cylinder 12.

(46) In use, the protection structure 100 and guard 118 are designed to protect the valve arrangement 16 and cylinder 14 from catastrophic and potentially dangerous damage during an impact scenario.

(47) The protection structure 100 was tested using a test method in which a gas cylinder assembly 10 is dropped in a controlled manner from a height of 1.2 m at an angle of 60° to a steel plate supported by concrete base. In this example, a 50 liter gas cylinder 12 is used, the cylinder 12 being filled with water to a weight of 100 kg.

(48) The drop test results were compared with simulated models to optimise the arrangement. To illustrate the operation of the protection device 100, FIGS. 11 and 12 show modelled results of two different impact scenarios.

(49) As shown in FIGS. 11 and 12, the impact has resulted in the desired deformation of the first section 102 of the protection structure 100. In contrast, the second section 104 is relatively un-deformed, save for a bending of the third flange 116 upon contact with the impact surface.

(50) Further, and importantly, the valve 16 is only plastically deformed by a relatively small, and safe, amount when compared to a similar impact without a protection structure 100 in place.

(51) In general, and by way of a non-limiting example, a plastic strain of greater than 8% will result in a test fail and a potential failure of the valve. In the example of FIG. 11, the plastic strain on the neck of the valve 16 was reduced to 5.4% from 12.1% by the use of the protection structure 100 and guard 118. In the example of FIG. 12, the plastic strain in the neck of the valve 16 was reduced from 9.6% to 5.8%, thus preventing the valve 16 from being plastically deformed to an unsafe degree.

(52) In addition, the use of the protection structure 100 spreads the impact forces out over a longer time period, reducing the peak shock experienced by the valve. This is one mechanism by which the protection structure 100 protects the valve.

(53) In summary, the present invention provides an energy absorbing device which can be integrated into a valve and guard package such that it forms a permanently or semi-permanently integrated part to connect the guard to the valve. Concomitantly, the costs and ergonomic constraints of the provision of a guard for a larger or heavier cylinder can be reduced when compared to known arrangements.

(54) Furthermore, the arrangement of the present invention enables the design of the energy absorber load transferring section to be used to strengthen locally the guard structure and to enable location and securing of the guard to the valve.

(55) Variations will be apparent to the skilled person would be readily aware of alternatives that would fall within the scope of the present application. For example, whilst the above embodiment has been described with reference to a protection structure, guard and valve assembly, the protection structure and guard may be supplied without the valve and retrofitted to existing valves and cylinders.

(56) Whilst the above embodiment has been described with reference to particular valve and gas cylinder arrangements, it is to be understood that the present invention is applicable to a range of suitable gas cylinder assemblies.

(57) In addition, the protection structure may be formed from different materials than those described in relation to the above embodiment. Other suitable materials may be: brass; aluminium; copper; or suitable alloys.

(58) Further, the first and second sections of the protection structure need not be formed from the same material. Dissimilar materials having different thicknesses or hardnesses may be used to provide the necessary deformability of the first section relative to the second section.

(59) The protection structure need not have the specific shape described. Cross-sectional shapes other than circular may be used; for example, square, oval or polygonal. In addition, the relative dimensions and proportions may be varied as appropriate to maintain the desired material and functional properties.

(60) In addition, whilst the second section is, in the described embodiment, shown to compress and buckle, other types of deformation mechanism are to be considered to be within the scope of the present invention. For example, the first section may be arranged to peel away from the second section which is deformed as a result.

(61) In addition, either the first or second sections may comprise an initiator or initiators to encourage particular deformation. For example, a shaped aperture, or particular section of material may be thinned to provide an engineered weak point around which deformation and/or fracture may be centred.

(62) The guard structure may differ from that shown and described without departing from the scope of the present invention. For example, the dependent lip need not extend around the entire circumference of the guard. In addition, alternative materials and structures may be used as appropriate.

(63) Embodiments of the present invention have been described with particular reference to the examples illustrated. While specific examples are shown in the drawings and are herein described in detail, it should be understood, however, that the drawings and detailed description are not intended to limit the invention to the particular form disclosed. It will be appreciated that variations and modifications may be made to the examples described within the scope of the present invention.