TECHNICAL FIELD

The present disclosure relates to a pressure reducer. More specifically, the present disclosure relates to a compact design of the pressure reducer.

BACKGROUND

Pressure reducers are found in many common domestic and industrial applications. For example, pressure reducers are used in gas grills to regulate propane, in home heating furnaces to regulate natural gases, in medical and dental equipment to regulate oxygen and anesthesia gases, in pneumatic automation systems to regulate compressed air, in engines to regulate fuel and in gardening systems to regulate irrigation among other application. As this partial list demonstrates there are numerous applications for pressure reducers yet, in each of them, the pressure reducers provide the same function. The pressure reducers reduce a supply (or inlet) pressure to a lower outlet pressure and work to maintain this outlet pressure despite fluctuations in the inlet pressure. The reduction of the inlet pressure to the lower outlet pressure is the key characteristic of the pressure reducers.

The pressure reducer includes a compression spring, a piston rod, and a diaphragm operatively coupled with the piston rod in a pressure reducer chamber. These components counteract fluid pressure and thereby control or regulate the outlet pressure of the pressure reducer. Further, a strength of the compression spring influences a maximum length of the pressure reducer as a strong compression spring requires a lot of installation space. Thus, there is a need for an intelligent spring design for the pressure reducer, which may substantially reduce the length of the pressure reducer without compromising with the strength of the spring and without affecting the overall working and efficiency of the pressure reducer.

An example of a pressure reducer with intelligent spring design is provided in United States patent 6,708,712 (hereinafter referred to as ’712 reference). The ’712 reference provides a pressure regulator having a disc spring. The pressure regulator includes a valve having a movable device that is positioned to control fluid flow through the pressure regulator. Downstream fluid pressure produces a first force acting on the movable device to close the valve to block fluid flow through the pressure regulator. The disc spring produces a second force that acts on the movable device to open the valve to enable fluid to flow through the pressure regulator. However, the ’712 seems short of disclosing the spring associated with the pressure reducer that may contribute to improve the stability of a few components within the pressure reducer in addition to providing forces for guiding the motion of the piston rod (or the movable member).

A further exemplary pressure reducer is disclosed in the PCT patent application WO 2012/104274 A2 (hereinafter referred to as the ‘274 reference). The ‘274 reference discloses a gas pressure and/or flow control device comprising a body, an actuating rod for actuating first gas shut-off means, sealing means between the body and the rod allowing movement of the rod, biasing means exerting an elastic force on the actuating rod, wherein the biasing means comprise a disk spring arranged concentrically with the rod, and wherein the sealing means comprise a first gas tight membrane attached to the body and to the rod. The first membrane is generally circular with a central hole. Its outer periphery is attached to the body and its inner periphery is attached to the rod. The disk spring is placed on the membrane so as to urge the rod downwardly in the sense of opening the shut-off valve of a first stage. The membrane and the disk spring can be held in place in their seat in the body by a crimping action of body material on an outer periphery of the disk spring respectively the membrane. The rod comprises a shoulder portion for supporting the inner opening respectively periphery of the membrane which is held in place by a crimping action of a collar formed at the upper or distal end of the rod. A lower surface of the collar holds the washer against the membrane. Further the legs of the disk spring are in contact with an upper surface of the rounded collar of the rod, thus allowing a direct contact with minimum frictional forces. Hence, the ‘274 reference unambiguously discloses that the membrane and the disk spring are crimped together at their outer peripheries, but are distanced to each other on the inner periphery respectively over their radial extension. Additionally, the diaphragm is supported by the housing respectively the shoulder portion as well as the collar. Furthermore, the ‘274 reference discloses that the disk spring solely functions for imparting forces on the rod. However, the ‘274 reference seems short of disclosing a spring associated with the pressure reducer that may contribute to improve the stability of a few components within the pressure reducer in addition to providing forces for guiding the motion of the piston rod (or the movable member). Particularly, the ‘274 reference seems short of disclosing a disk spring which is configured at the same time for imparting forces on a piston rod as well as for operatively supporting a diaphragm.

A further exemplary pressure reducer is disclosed in US patent application US 3,482,591 Al (hereinafter referred to as ‘591 reference). The ‘591 reference discloses a pressure regulator valve assembly comprising a housing within which there is disposed a valve and a movable diaphragm with and against which is disposed a cup-shaped backing plate. A disc spring acts through the cup-shaped backing plate to bias the diaphragm in a direction to unseat the valve. One side of the diaphragm fluidly communicates with a regulating chamber and the other side of the diaphragm is exposed to a reference chamber which communicates with the ambient. A cover portion of the housing clamps the periphery of the diaphragm, thus providing a seal at the diaphragm’s periphery. The diaphragm has a central aperture through which a hollow stem projects. The spring disc has a central aperture in which a further stem is fixedly secured so as to preclude relative rotation. The further stem is moved axially in and out, thereby changing the bias on the disc spring to select the regulating pressure. Hence, the ‘591 reference unambiguously discloses that the spring disc is used to select the regulating pressure. Additionally, the ‘591 reference discloses that the diaphragm is supported over its radial extension by the cup-shaped backing plate. However, the ‘591 reference seems short of disclosing the spring associated with the pressure reducer that may contribute to improve the stability of a few components within the pressure reducer in addition to providing forces for guiding the motion of the piston rod (or the movable member). Particularly, the ‘591 reference seems short of disclosing a disc spring which is configured at the same time for imparting forces on a piston rod as well as for supporting a diaphragm. Thus, there is a need for an improved design of the pressure reducer such that the pressure reducer includes the spring that improves the overall stability and performance of the pressure reducer in addition to executing its general application of imparting the forces to the piston rod for guiding the motion of the piston rod.

SUMMARY

In view of the above, it is an objective of the present invention to solve or at least reduce the drawbacks discussed above. The objective is at least partially achieved by a pressure reducer for reducing a fluid pressure. The pressure reducer includes a pressure reducer body defining at least one pressure reducer chamber. The pressure reducer chamber includes an inlet section and an outlet section fluidly coupled with the inlet section such that the inlet section and the outlet section allow inlet and outlet of the fluid respectively. The pressure reducer chamber further includes a disc spring defining an inner diameter and an outer diameter. A piston rod is coupled with the disc spring and a diaphragm is operatively coupled with the piston rod. The pressure reducer is characterized in that the disc spring operatively supports the diaphragm and requires less space for installation in the pressure reducer chamber, and wherein the disc spring is configured to impart forces on the piston rod as well as to support the diaphragm.

Thus, the present disclosure provides an improved pressure reducer that advantageously includes the disc spring coupled with the piston rod. The disc spring is designed to provide the strength like that provided by a conventional compression spring. Further, the disc spring allows for compact or short design of the pressure reducer as the disc spring requires relatively very less installation space inside the pressure reducer when compared to the installation space required by a compression spring. The disc spring also serves as support for the diaphragm and prevents the diaphragm from slipping out due to fluid force. Further, the disc spring is easy, cost-effective, and timesaving in manufacturing.

According to an embodiment of the present disclosure, the disc spring is a slotted disc spring. The slotted disc spring defines slots on the inner diameter and the outer diameter such that the slotted disc spring is adapted to allow the piston rod to exhibit a stroke of 3 mm. The slots in the slotted disc spring improves its flexibility and allows the piston rod to exhibit an oscillating motion within the pressure reducer chamber.

According to an embodiment of the present disclosure, the slotted disc spring is adapted to engage with an annular groove in the piston rod. Further, the pressure reducer body defines an annular recess for supporting the slotted disc spring. Thus, the slotted disc spring is installed within the pressure reducer chamber in a stable manner via virtue of the annular groove in the piston rod and the annular recess in the pressure reducer body.

According to an embodiment of the present disclosure, the pressure reducer generates a constant output pressure of 4 bars. Further, in some embodiments, the pressure reducer generates a constant output pressure of 1.5 bars. The constant output pressure may be pre-determined and preset during the manufacturing of the pressure reducer according to the application requirements of the pressure reducer. For example, the constant output pressure of 1.5 bars is well suited and optimal for the operation of drip heads and spray nozzles used for gardening operations.

According to an embodiment of the present disclosure, a valve selectively allows and disallows passage of fluid via the inlet section. The valve selectively allows the passage of fluid to the outlet section such as to maintain a constant output pressure of the pressure reducer. The piston rod oscillates to momentarily block the supply of fluid from the inlet section towards the outlet section.

According to an embodiment of the present disclosure, the pressure reducer is used for drip-irrigation. The pressure reducer of the present disclosure finds its application with the gardening operations such as, but not limited to, dripirrigation. However, the pressure reducer of the present disclosure is not restricted with its application area. The pressure reducer may conveniently and efficiently be used for any domestic or industrial application.

Other features and aspects of this invention will be apparent from the following description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described in more detail with reference to the enclosed drawings, wherein:

FIG. 1 shows a perspective view of a pressure reducer assembly, in accordance with an aspect of the present disclosure;

FIG. 2 shows a cross-section view of a pressure reducer assembly, in accordance with an aspect of the present disclosure;

FIG. 3A shows a perspective view of a slotted disc spring, in accordance with an aspect of the present disclosure;

FIG. 3B shows a perspective view of a slotted disc spring and a piston rod, in accordance with an aspect of the present disclosure;

FIG. 3C shows a perspective view of a slotted disc spring and a diaphragm coupled with a piston rod, in accordance with an aspect of the present disclosure;

FIG. 3D shows a cross-section view of a pressure reducer, in accordance with an aspect of the present disclosure;

FIG. 4A shows a cross-section view of a pressure reducer with a slotted disc spring, in accordance with an aspect of the present disclosure;

FIG. 4B shows a cross-section view of a pressure reducer with a compression spring, in accordance with an aspect of the present disclosure;

FIG. 5A shows a cross-section view of a pressure reducer showing an upward stroke of a piston rod; and

FIG. 5B shows a cross-section view of a pressure reducer showing a downward stroke of a piston rod, in accordance with an aspect of the present disclosure.

DESCRIPTION OF EMBODIMENTS

The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments of the invention incorporating one or more aspects of the present invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. For example, one or more aspects of the present invention may be utilized in other embodiments and even other types of structures and/or methods. In the drawings, like numbers refer to like elements.

Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, "upper", "lower", "front", "rear", "side", "longitudinal", "lateral", "transverse", "upwards", "downwards", "forward", "backward", "sideward", "left," "right," "horizontal," "vertical," "upward", "inner", "outer", "inward", "outward", "top", "bottom", "higher", "above", "below", "central", "middle", "intermediate", "between", "end", "adjacent", "proximate", "near", "distal", "remote", "radial", "circumferential", or the like, merely describe the configuration shown in the Figures. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.

FIG 1 illustrates a pressure reducer 100. The pressure reducer 100 of the present disclosure is used for reducing a fluid pressure of the fluid intended to be used for drip-irrigation or other gardening operations. However, the pressure reducer 100 of the present disclosure is not restricted with its application area. The pressure reducer 100 may conveniently and efficiently be used for any other domestic or industrial applications.

Further, the fluid used with the pressure reducer 100 may be a liquid (say water) or a gas (say air) depending on the application requirement of the pressure reducer 100. The fluid may selectively be provided by a fluid source (not shown) at a pressure equal to more than the output pressure requirements of the application for which the pressure reducer 100 is used.

The fluid source may advantageously be provided with a valve such as to regulate the outflow of the fluid from the fluid source. Further, the fluid source may be provided with an automatic operatable accessory that may automatically regulate the outflow of the fluid from the fluid source. For example, the fluid source may be provided with a watering computer when the fluid is a water. The watering computer may allow and regulate outflow of the water from the fluid source (or water source) depending upon the time of the day, preset water outflow timings, among other factors.

The fluid source may be fluidly coupled to the pressure reducer 100 via a hose or any other means commonly known and understood in the related art without limiting the scope of the present disclosure. In some embodiments, the fluid source may be fluidly coupled to a plurality of pressure reducers 100 by way of fluid distributors (commonly available in the related art).

The pressure reducer 100, as illustrated in FIGS. 1 and 2, includes a pressure reducer body 110. The pressure reducer body 110 of the present disclosure is a cylindrical body having a central axis X-X’ along a longitudinal direction of the pressure reducer 100. However, in actual implementation of the present disclosure, the pressure reducer body 110 may have any other shape without restricting the scope of the present disclosure. The pressure reducer body 110 may be made of brass, plastic, and aluminum. Various grades of stainless steel (such as 303, 304, and 316) may also be used for the manufacture of the pressure reducer body 110. However, any other material available to handle various fluids and operating environments may be employed for making or manufacturing the pressure reducer body 110. Further, any suitable manufacturing process may be employed for manufacturing of the pressure reducer body 110 without restricting the scope of the present disclosure.

The pressure reducer body 110 defines at least one pressure reducer chamber 120. The pressure reducer chamber 120 includes an inlet section 122 and an outlet section 124 fluidly coupled with the inlet section 122 such that the inlet section 122 and the outlet section 124 allow inlet and outlet of the fluid respectively. The inlet section 122 is defined along a central axis Y-Y’ and the outlet section 124 is defined along a central axis Z-Z’. In some embodiments, as shown in FIG. 2, the central axes Y-Y’, Z-Z’ and X-X’ coincide with each other along the longitudinal direction of the pressure reducer 100. In some embodiments, the central axes Y-Y’, Z-Z’ and X-X’ may be parallel to each other but may not necessarily coincide with each other. In some embodiments, the central axes Y-Y’,L ^r -Z' ^> and the X-X’ may have any other angular orientation with respect to each other or with respect to the longitudinal direction of the pressure reducer 100 without restricting the scope of the present disclosure in any manner.

The inlet section 122 is fluidly coupled to the fluid source via a coupling nipple 126, as shown in FIGS. 1 and 2. The coupling nipple 126 may advantageously be designed in a manner such that the coupling nipple 126 selectively allows passage of fluid therethrough (received from the fluid source) only when it is fluidly coupled with the inlet section 122 of the pressure reducer 100. Such a design of the coupling nipple 126 may substantially prevent fluid leakages when the pressure reducer 100 is not operational or not in use. In some embodiments, the inlet section 122 may be sealingly coupled to the coupling nipple 126. The sealing may be provided by a sealing gasket, O-ring, or any other known and easily available sealing means (or sealing element).

The inlet section 122 further includes a threaded portion 123 such that the threaded portion 123 threadedly engages with a complimentary threaded portion 127 of the coupling nipple 126. Thus, in the preferred embodiment of the present disclosure, the inlet section 122, and the coupling nipple 126 are threadedly engaged or coupled with each other. However, in actual implementation of the present disclosure, the fluid coupling between the inlet section 122 and the coupling nipple 126 may be accomplished by any suitable means known and understood in the related art.

In the preferred embodiment of the present disclosure, as illustrated in FIG. 2, the inlet section 122 further includes a filter element 125. The filter element 125 may be operatively coupled to the inlet section 122 such that the filter element 125 filters the fluid received from the fluid source before it enters the pressure reducer chamber 120. The filter element 125 prevents clogging of the inlet section 122 and thereby promotes smooth operations of the pressure reducer 100. The filter element 125 may be coupled to the inlet section 122 by any means known in the related art. For example, the filter element 125 may be glued to the inlet section. Further, the filter element 125 may have any shape, size, and type as per the application requirements. In some embodiments, the filter element 125 may be a surface filter made of closely woven fabric or treated paper with a uniform pore size. Fluid from the fluid source flows through the pores of the filter element 125 and contaminants are stropped on the filter element surface. In some embodiments, the filter element 125 may be a depth filter made of layers of fabric or fibers, which provide many tortuous paths for the fluid to flow through. The pores or passages are larger than the rated size of the filter element 125 for particles to be retained in the depth of the media rather than on the surface. In some embodiments, the filter element 125 may be of the 5-micron, woven mesh, micronic, porous metal, or magnetic type. The micronic and 5-micron elements have non-cleanable filter media and may be disposed of when they are removed whereas the porous metal, woven mesh and magnetic filter elements are designed to be cleaned and reused.

Further, as illustrated in FIG. 2, the inlet section 122 includes a valve 129. The valve 129 selectively allows the fluid from the fluid source to pass through the pressure reducer chamber 120. The valve 129 selectively allows and disallows passage of fluid via the inlet section 122. The valve 129 selectively allows the passage of fluid to the outlet section 124 such as to maintain constant output pressure of the pressure reducer 100. The valve 129 is located downstream of the filter element 125 in the direction of the fluid flow. The valve 129 may be coupled to the inlet section 122 by any suitable means known in the art. However, in the preferred embodiment, the valve 129 is screwed into the inlet section 122. The screw coupling between the valve 129 and the inlet section 122 allows for movement of the valve 129 relative to the inlet section along the longitudinal direction of the pressure reducer 100. The movement of the valve 129 along the longitudinal direction of the pressure reducer 100 may also help in adjusting the constant output pressure generated by the pressure reducer 100.

In some embodiments, the valve 129 may be along the central axis X-X’ of the pressure reducer body 110. In some embodiments, the valve 129 may be along the central axis Y-Y’ of the inlet section 122. In some embodiments, the valve 129 may be parallel to the central axis X-X’ of the pressure reducer body 110. In some embodiments, the valve 129 may be offset to the central axis X-X’ of the pressure reducer body 110. In some embodiments, the valve 129 may be at an angle to the central axis X-X’ of the pressure reducer body 110. In some embodiments, the valve 129 may be parallel to the central axis Y-Y’ of the inlet section 122. In some embodiments, the valve 129 may be offset to the central axis Y-Y’ of the inlet section 122. In some embodiments, the valve 129 may be at an angle to the central axis Y-Y’ of the inlet section 122. The valve 129 may have orientation relative to the longitudinal direction of the pressure reducer 100 without restricting the scope of the present disclosure in any manner.

The valve 129 further includes a seal 130. The seal 130 may be O-ring or any other type of seal generally available in the related art. In some embodiments, the seal 130 may be a flat seal. In some embodiments, the seal 130 may be a radial seal, i.e., providing sealing of the fluid in the radial direction.

With continued reference to FIG. 2, the pressure reducer chamber 120 further includes a spring- operated piston rod 121. The piston rod 121 is a hollow rod allowing passage of the fluid of which the pressure is to be reduced in the pressure reducer 100. The piston rod 121 has a center “Cl” along the central axis X-X’ when the piston rod 121 is assembled in the pressure reducer chamber 120. Further, the piston rod 121 has an inner diameter “A” and an outer diameter “B”. In some embodiments, the inner diameter “A” may be 0.6 times of the outer diameter “B”. In some embodiments, the inner diameter “A” may be 0.45 times of the outer diameter “B”. In some embodiments, the inner diameter “A” may be equivalent to the outer diameter “B”.

The spring 131 is a disc spring 131 such that the piston rod 121 is coupled with the disc spring 131. The disc spring 131 is compact in structure and easy to manufacture. In the preferred embodiment of the present disclosure, the disc spring is a slotted disc spring 131 and same will be used in the rest of the disclosure for understanding of the present disclosure. The slotted disc spring 131 is used to operate the piston rod 121 in the pressure reducer chamber 120. As illustrated in FIG. 3A, the slotted disc spring 131 defines an inner diameter “DI”, an outer diameter “D2” and a center “C2” defined along a central axis W-W’. The inner diameter “DI” and the outer diameter “D2” are the inner and the outer diameter of the slotted disc spring 131 when it is not coupled to the piston rod 121. The relationship between the inner diameter “DI” and the outer diameter “D2” may depend on variety of factors such as, but not limited to, dimensions of the pressure reducer body 110, the pressure reducer chamber 120, the piston rod 121, the slotted disc spring 131 strength requirements, the piston rod 121 stroke requirements, among other factors.

In some embodiments, the outer diameter “D2” may be twice the inner diameter “DI”. In some embodiments, the outer diameter “D2” may be thrice the inner diameter “DI”. In some embodiments, the outer diameter “D2” may be 1.5 times the inner diameter “DI”. In some embodiments, the inner diameter “DI” of the slotted disc spring 131 may be equivalent to the outer diameter “B” of the piston rod 121. In some embodiments, the inner diameter “DI” of the slotted disc spring 131 may be less than outer diameter “B” of the piston rod 121. In some embodiments, the inner diameter “DI” of the slotted disc spring 131 may be equivalent to the inner diameter “A” of the piston rod 121. In some embodiments, the inner diameter “DI” of the slotted disc spring 131 may be less than outer diameter “B” but greater than the inner diameter “A” of the piston rod 121. In some embodiments, the outer diameter “D2” of the slotted disc spring 131 may be twice the outer diameter “B” of the piston rod 121. However, the inner diameter “DI”, the outer diameter “D2”, the inner diameter “A” and the outer diameter “B” may have any other relation relative to each other without limiting the scope of the present disclosure in any manner.

Further, as illustrated in FIG. 3A, the slotted disc spring 131 defines slots 150, 160 on the inner diameter “DI” and the outer diameter “D2” respectively. The slots 150, 160 creates a lever which works on the unslotted portion of the spring. This has an effect of reducing the spring load and increasing the deflection of the spring.

In some embodiments the slots 150, 160 (as shown in FIG. 3A) may be a plurality of equidistant slots on the surface of the slotted disc spring 131. In some embodiments, the slots 150 may be equidistant slots on the surface of the slotted disc spring 131 but the slots 160 may be formed at unequal distances on the surface of the slotted disc spring 131. In some embodiments, the slots 160 may be equidistant slots on the surface of the slotted disc spring 131 but the slots 150 may be formed at unequal distances on the surface of the slotted disc spring 131. In some embodiments, the slots 150, 160 may be formed at unequal distances on the surface of the slotted disc spring 131.

In some embodiments, the plurality of slots 150 may have same shapes and sizes as the plurality of slots 160. In some embodiments, the plurality of slots 150 may have shapes and sizes different to the plurality of slots 160. In some embodiments, all the plurality of slots 150 may have same shapes and sizes. In some embodiments, all the plurality of slots 150 may have different shapes and sizes. In some embodiments, a few of the plurality of slots 150 may have same shapes and sizes. In some embodiments, all the plurality of slots 160 may have same shapes and sizes. In some embodiments, all the plurality of slots 160 may have different shapes and sizes. In some embodiments, a few of the plurality of slots 160 may have same shapes and sizes. In some embodiments, there may slots on the on the inner diameter “DI” only. In some embodiments, there may slots on the on the outer diameter “D2” only.

The design of the slotted disc spring 131 may have any kind of arrangement as discussed above as per the application requirement of the slotted disc spring 131. The design may be such that the slotted disc spring 131 may have strength enough to operate the piston rod 121 for efficient working or operation of the pressure reducer 100. Further, the material of the slotted disc spring 131 may be such that it reacts to loading (load due to the fluid in the pressure reducer 100) by elastic deformation. The slotted disc spring 131 may be formed from steel or any other suitable material known and understood in the related art. Further, the slotted disc spring 131 may be formed from manufacturing processes, such as, but not limited to, stamping. The stamping process is cost-effective, fast and demands little labor as well as machine operation. Further, the stamping process reduces material wastage, improves accuracy and may be automated.

Further, as illustrated in FIGS. 3B and 3C, the slotted disc spring 131 is forced over the piston rod 121 by any means known in the art so that the central axis X-X’ coincides with the central axis W-W’. In some embodiments, as shown in FIG. 3D, the central axis W-W’ coincides with the central axes X-X’, Y-Y’ and Z-Z’. In some embodiments, the central axis W-W’ may coincide with the central axis X-X’ and one of the central axes Y-Y’ or Z-Z’. In some embodiments, the central axis W-W’ may coincide only with the central axis X-X’. The slotted disc spring 131 of the present disclosure is adapted to allow the piston rod 121 to exhibit a stroke of 3 mm during the working of the pressure reducer 100. However, in actual implementation of the present disclosure, the stroke length may be varied as per the application requirements during manufacturing of the pressure reducer 100 by varying the design parameters of the slotted disc spring 131.

The slotted disc spring 131, as illustrated in FIG. 4A, allows for compact or short design of the pressure reducer 100 as the slotted disc spring 131 requires relatively very less installation space inside the pressure reducer 100 when compared to the installation space required by the compression spring 131’ (as shown in FIG. 4B) providing equal strength. The length “L” of the pressure reducer body 110 is reduced by a magnitude “Z” when the compression spring 131’ within the pressure reducer body 110 is advantageously replaced by the slotted disc spring 131. The length “L” of the pressure reducer body 110 is reduced to length “L - Z” when the compression spring 131’ within the pressure reducer body 110 is replaced by the slotted disc spring 131. The magnitude “Z” depends on the dimensions of the length of the slotted disc spring 131. The magnitude “Z” may vary as per the strength requirement of the slotted disc spring 131 to be used with the pressure reducer 100.

Further, as illustrated in FIGS. 3B and 3C, the slotted disc spring 131 is adapted to engage with an annular groove 170 in the piston rod 121. The annular groove 170 allows for easy installation of the slotted disc spring 131 with the piston rod 121. The annular groove 170 allows for easy and secure coupling of the slotted disc spring 131 with the piston rod 121. Further, an annular recess 180, as illustrated in FIGS. 5A and 5B, is defined by the pressure reducer body 110 for supporting the slotted disc spring 131. The annular recess 180 may additionally assist in centering of the slotted disc spring 131 in the pressure reducer chamber 120. The annular recess 180 provides linear support to the slotted disc spring 131. Thus, the slotted disc spring 131 is installed within the pressure reducer chamber 120 in a stable manner via virtue of the annular groove 170 in the piston rod 121 and the annular recess 180 in the pressure reducer body 110.

Further, the piston rod 121 (as illustrated in FIGS. 2, 3B, 3C, 3D, 5A and 5B) may be concentric with the pressure reducer body 110 or the pressure reducer chamber 120. In some embodiments, the piston 121 may have any other orientation relative to the earlier defined central axes X-X’, Y-Y’ and Z-Z’ in accordance with the operational feasibility of the pressure reducer 100. The piston rod 121 of the present disclosure is configured to oscillate back and forth substantially within the pressure reducer chamber 120. The back-and-forth motion of the piston rod 121 is due to differential force experienced by the piston rod 121. The force experienced by the piston rod 121 is due to the slotted disc spring 131 and a diaphragm 128 operatively coupled with the piston rod 121 in the pressure reducer chamber 120.

The diaphragm 128 is coupled to the piston rod 121 by virtue of a groove 190 in the piston rod 121. The diaphragm 128 is clamped on the annular groove 190 formed on an outer surface of the piston rod 121. The diaphragm 128 is additionally supported by the slotted disc spring 131. The slotted disc spring 131 operatively supports the diaphragm 128. Thus, the spring 131 of the present disclosure is advantageously utilized in the pressure reducer chamber 120 for imparting forces on the piston rod 121 as well as for supporting the diaphragm 128 whereas the spring 131 in the prior art only impart forces on the piston rod 121.

The slotted disc spring 131 further prevents slippage of the diaphragm 128 away from the piston rod 121 due to the fluid pressure or force in the pressure reducer 100. The slotted disc spring 131 provides a resting surface to the diaphragm 128 without any height offset. In some embodiments, the shape and size of the diaphragm 128 may be similar to the slotted disc spring 131. In some embodiments, the shape and size of the diaphragm 128 may be different to that of the slotted disc spring 131. In some embodiments, there may be more than one slotted disc spring 131 for supporting the diaphragm 128. In some embodiments, the slotted disc spring 131 may be placed on a plane parallel to a plane of the diaphragm 128. In some embodiments, the slotted disc spring 131 may be placed on the plane at an angle to the plane of the diaphragm 128.

In some embodiments, the diaphragm 128 may be made of material similar to that of the slotted disc spring 131. In some embodiments, the diaphragm 128 may be made of material different to that of the slotted disc spring 131. In some embodiments, the method or process for manufacturing the diaphragm 128 and the slotted disc spring 131 may be same. In some embodiments, the method or process for manufacturing the diaphragm 128 and the slotted disc spring 131 may be different. The process of manufacturing may preferably be stamping due to the advantages as already discussed above.

The direction of motion of the piston rod 121 at any particular time instant is governed by the direction of net force generated upon the piston rod 121 by the slotted disc spring 131 and the diaphragm 128. For example, the piston rod 121 moves in upstream direction when the net force is in upstream direction due to higher magnitude of force generated by the diaphragm 128 relative to the force generated by the spring 131.

The constant output pressure generated by the pressure reducer 100 may be adjusted by varying the initial distance or the gap between the piston rod 121 and the seal 130 during the manufacturing of the pressure reducer 100. For example, the constant output pressure may be pre-determined and preset during the manufacturing of the pressure reducer according to the application requirements of the pressure reducer 100. Some applications may demand the constant output pressure of 4 bars while other applications such as drip heads and spray nozzles used for gardening operations may demand the constant output pressure of 1.5 bars. Accordingly, the initial distance or the gap between the piston rod 121 and the seal 130 is increased for generating constant output pressure of 4 bars while it is comparatively reduced for generating constant output pressure of 1.5 bars.

With continued reference to FIG. 2, the pressure reducer body 110 includes a first threaded portion 112 on its outside surface facing opposite to the pressure reducer chamber 120. The first threaded portion 112 may be used for coupling the pressure reducer body 110 with other accessories of the pressure reducer 100. The pressure reducer body 110 further includes a pressure compensation hole 114 in the first threaded portion 112. The pressure compensation hole 114 ensures unrestricted mobility of the piston rod 121. The pressure compensation hole 114 allows release of air pressure generated in the pressure reducer chamber 120 when the piston rod 121 moves in the upstream direction of the fluid flow in the pressure reducer 100. The pressure compensation hole 114 allows air to escape from the pressure reducer chamber 120 when the piston rod 121 moves in the upstream direction of the fluid flow in the pressure reducer 100. Conversely, the pressure compensation hole 114 allows suction of the surrounding air (external to the pressure reducer 100) when the piston rod 121 moves in the downstream direction of the fluid flow in the pressure reducer 100.

In some embodiments, the pressure compensation hole 114 is a circular hole. The hole is preferably circular as it is easy to drill a circular hole. Further, it substantially prevents material wastage when compared with manufacturing or producing holes of other shapes. However, the hole may have any other suitable shape without restricting the scope of the present disclosure.

In some embodiments, air in the pressure reducer chamber 120 surrounding the spring-operated piston rod 121 is sealed from the valve 129 using a sealing element 133. The sealing element 133 prevents mixing of air in the pressure reducer chamber 120 with the fluid introduce in the pressure reducer 100 via the inlet section 122. The sealing element 133 may be O-ring or any other commonly available sealing element known in the art without restricting the scope of the present disclosure.

Further, a flange 132 is sealingly coupled with the pressure reducer body 110 such that the sealing disallows the backflow of fluid past the outlet section 124. The flange 132 is concentric with the pressure reducer body 110. The diaphragm 128 seals the coupling between the flange 132 and the pressure reducer body 110. The boundaries or the extremities of the diaphragm 128 are abutted or pressed between the flange 132 and the pressure reducer body 110, thereby providing a fluid-tight sealing. The fluid tight sealing is the outcome of the contact pressure exerted on the diaphragm 128 due to the coupling between the flange 132 and the pressure reducer body 110.

The sealing prevents or disallows the backflow of fluid past the outlet section 124, thereby eliminating any possible leakage and improving the overall efficiency of the pressure reducer 100. Further, the multiple usage or application of the diaphragm 128 means no separate sealing elements such as O-rings are required for the sealing. Hence, the pressure reducer 100 is easy to assemble with all its necessary components or accessories with further advantage of lower manufacturing expenses due to less components or material required for the assembly or manufacturing of the pressure reducer 100. Further, due to less components, pressure reducer maintenance cost is also reduced. Furthermore, the sealing may prevent ingress of air in the outlet section 124, thereby preventing mixing of air drawn-in from the compensation hole with the fluid (say liquid).

The flange 132 has a second threaded portion 134 complimentary to the first threaded portion 112 such that the pressure reducer body 110 and the flange 132 are threadedly coupled to each other through the first and the second threaded portion 112, 134. The flange 132 further includes a third threaded portion 136. The third threaded portion 136 is formed on an outer surface of the flange 132 contrary to the second threaded portion 134, which is formed on an inner surface of the flange 132. The third threaded portion 136 faces the pressure reducer body 110 while the second threaded portion 134, faces away from the pressure reducer body 110 in an opposite direction.

The second threaded portion 134 couples the flange 132 with the pressure reducer body 110 whereas the third threaded portion 136 couples the flange 132 with a connector 138 (or a nipple 138). The connector 138 may complete the pressure reducer assembly and may allow the fluid with the reduced pressure to be transported for various domestic and industrial applications. The coupling between the flange 132 and the connector 138 is a threaded coupling due to threaded engagement of the third threaded portion 136 and a threaded portion 140 of the connector 138. However, in some embodiments, the coupling between the flange 132 and the connector 138 may be due to any other coupling means known and understood in the related art.

In operation, the fluid from the fluid source enters the pressure reducer 100 at high pressure from the inlet section 122. The fluid is filtered using filter element 125 before it reaches the valve 129. The valve 129 selectively allows the passage of the fluid towards the spring-operated hollow piston rod 121. The fluid from the piston rod 121 flows outwards towards the flange 132 and finally towards the connector 138 for use with various domestic and industrial applications.

The pressure of the high-pressure fluid from the fluid source is reduced by the oscillating motion of the piston rod 121 (as shown in FIGS. 5A and 5B) substantially within the pressure reducer chamber 120. The piston rod 121 oscillates (performs an upward stroke (as shown in FIG. 5A) and a downward stroke (as shown in FIG. 5B) to reduce the fluid pressure to the constant output pressure. The piston rod 121 momentarily block the supply of fluid (as shown in FIG. 5B) from the inlet section 122 towards the outlet section 124. The piston rod 121 blocks the supply of fluid by engagement with the seal 130 of the valve 129. The seal 130 may axially or radially seal the piston rod 121 to prevent the fluid from entering the piston rod 121.

The piston rod 121 momentarily blocks the supply of fluid from the inlet section 122 when it is pressed by the diaphragm 128 against the spring force towards the upstream direction of the fluid flow. Further, the fluid may also lose some energy when the fluid presses the diaphragm 128 such that diaphragm further presses the piston rod 121 to make it move towards the upstream direction of the fluid flow. This way, the high fluid pressure is reduced to the final output pressure.

Further, when the fluid pressure near the output section 124 is reduced to the final value, the slotted disc spring 131 may overcome the force of the diaphragm 128 such that the piston rod 121 moves in the downstream direction towards its original position. The oscillating movement of the piston rod 121 is assisted by the pressure compensation hole 114 as already discussed above.

Thus, the present disclosure provides an improved pressure reducer 100 that is simple in construction and easy to install. The pressure reducer 100 advantageously includes the slotted disc spring 131 coupled with the piston rod 121. The slotted disc spring 131 is designed to provide the strength like that provided by a conventional compression spring 131’. Further, the slotted disc spring 131 allows for compact or short design of the pressure reducer 100 as the slotted disc spring 131 requires relatively very less installation space inside the pressure reducer 100 when compared to the installation space required by the compression spring 131’. The slotted disc spring 131 also serves as support for the diaphragm 128 and prevents the diaphragm 128 from slipping out due to fluid force. Further, the slotted disc spring 131 is easy, cost-effective, and timesaving in manufacturing.

In the drawings and specification, there have been disclosed preferred embodiments and examples of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation of the scope of the invention being set forth in the following claims.

LIST OF ELEMENTS

100 Pressure Reducer

110 Pressure Reducer Body

112 First Threaded Portion

114 Pressure Compensation Hole

120 Pressure Reducer Chamber

121 Piston Rod

122 Inlet Section

123 Threaded Portion

124 Outlet Section

125 Filter Element

126 Coupling Nipple

127 Threaded Portion

128 Diaphragm

129 Valve

130 Seal

131 Spring/Disc Spring/Slotted Disc Spring

131’ Compression Spring

132 Flange

133 Sealing Element

134 Second Threaded Portion

136 Third Threaded Portion

138 Connector/Nipple

140 Threaded Portion

150, 160 Slots

170 Annular Groove 180 Annular Recess

190 Groove

X-X’ Central Axis

Y-Y’ Central Axis

Z-Z’ Central Axis

W-W’ Central Axis

DI Inner Diameter

D2 Outer Diameter

Cl Center

C2 Center

A Inner Diameter

B Outer Diameter

L Length

Z Magnitude