BACKGROUND

[001] The present invention relates generally to equipment and processes associated with pressurized containers, and more particularly, with regard to liquid bulk gas containers.

[002] Dewars, tanks, and other containers store gas in liquid form for use in beverage, electronics, heat treating, and packaging industries, among others. In most applications, the liquid is maintained at very cold temperatures. When needed, the liquid is warmed to change its state to gas as required by a user. In smaller commercial applications, an evaporator typically made from copper or stainless steel coils internal to the container is used to warm the liquid.

[003] The containers conventionally have a maximum draw rate, which is derived from the size and capability of the evaporating coils. For instance, a dewar may have a maximum draw rate of forty pounds per hour of liquid converting to gas. Exceeding the maximum draw rate can result in the coils being unable to conduct and retain enough heat to prevent a tank from freezing up and blocking the flow altogether. In some cases, the maximum draw rate may be exceeded not just by overzealousness, but by leaks in regulators and pipes connected to the tank. A frozen tank requires replacement or a lengthy and costly thawing out period, during which time the operation must be stopped.

SUMMARY

[004] According to a particular embodiment, an apparatus includes a first flow path configured to allow a through flow of gas, wherein the first flow path includes a first pressure, an obstructing module; and a biasing mechanism configured to position the obstructing module within the flow path to mechanically limit the through flow in physical response to the first pressure incident on the biasing mechanism.

[005] According to another specific implementation, a first flow path includes an input port; and a container having an internal evaporator configured to convert a liquid into a gas flow provided to the input port, wherein the first flow path includes a first pressure; and a check valve configured to at least partially limit the through flow based on the first pressure.

[006] According to another particular embodiment, a method manufacturing a system to regulate gas flow from a liquid bulk gas container, the method including providing first and second pathways each configured to connect an inlet and an outlet; positioning a first needle valve along the first pathway; setting flow restriction using the first needle valve; coupling a second needle valve along the second pathway; setting a high pressure flow setting using the second needle valve; and positioning an adjustable check valve along the second pathway to selectively connect the inlet to the outlet.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[007] FIG. 1 is a schematic of an embodiment of a freeze protection system for a liquid bulk gas container;

[008] FIG. 2 is a block diagram of another embodiment of a freeze protection system for use with a liquid bulk container;

[009] FIG. 3 is a perspective view of an embodiment of a regulator system that includes needle valves and an adjustable check valve; and

[0010[ FIG. 4 is a method of manufacturing a freeze protection system for a liquid bulk gas container as could be performed by the systems of Figures 1-3.

DETAILED DESCRIPTION

[0011] An embodiment of a system for regulating a flowrate and pressure of a fluid or gas includes an orifice or limiting valve and a spring-loaded ball to mechanically limit the flow of a gas being released through the apparatus. According to one example, when pressure within the valve system (i.e., incoming from a connected container) falls below a predetermined level, a biasing mechanism, such as a spring and ball check valve, may obstruct one or more flow paths. The limited airflow path condition may reduce the flowrate and allow pressure to build back up within the valve system. [0012] In one specific example, when pressure near an inlet of the valve is 180 pounds per square inch (psi), the gas may flow through a first path and a second path. As the resultant pressure drops, the spring biasing mechanism may become stronger than the incoming pressure. As such, the ball may obstruct gas fluid flow within the second flow path. In this manner, the gas fluid flow may be restricted below a maximum flow rate to allow pressure to build back up within the valve system.

[0013] An initial pressure setting may be based on a tank sizing, capacity, and/or the composition of a gas. In an embodiment of the system, a low pressure flow setting may be set at about 10% below a rated evaporation flowrate of the tank or other container. The setting may be made at a factory or by a user in the field.

[0014] A high pressure flow setting may be set to a safe flowrate above as rated evaporation flowrate capacity of the tank. For example, a safe flowrate may be based on a site requirement. As with the initial pressure setting, the high pressure flow setting may be ordered from a factory and adjusted as desired in the field. An illustrative tank flowrate set point may be factory set to 5-10 % above an expected maximum evaporation flowrate of the tank.

[0015] During normal operation, gas demands of an embodiment of the system may remain less than an evaporation rate capacity. Gas pressure may be operating at a level above the tank pressure set point, and temperatures may be within a normal operational range. Gas flow may occur through only a first low flow port. When gas flow is needed, the gas may flow through the first flow path at the regulated flow rate. The flow rate may limited by a first needle valve on positioned along a first flow path.

[0016] During high flow conditions (e.g., while operating in high flow mode), gas demand may exceed the flow capacity of the first flow port. Additionally, the available tank gas pressure may be above the tank pressure set point. Flow may occur via the first flow path via the first port. Concurrently, gas demand may be provided via the second port up to an additional set point capability. An illustrative set point capability may be set by a factory or user. Flow from the second port may be due to the tank gas pressure being greater than a cracking pressure. The cracking pressure may equal an amount of pressure capable of opening a check valve. An illustrative check valve may include a ball and spring device, solenoid, or other biasing mechanism. This cracking pressure feature may yield a total max flow that equals a first flow of the first flow path plus a second through flow of the second flow path.

[0017] When in a protective mode, the gas demand may remain in a high flow mode long enough for an available gas pressure to drop below the tank pressure set point. This condition may occur because the evaporator cannot keep up with the gas demand. The liquid may be at a lower pressure than the gas. So when the gas pressure drops below the set point, the cracking pressure may be above the tank gas pressure, and the check valve may cut off gas flow through the second port. Gas flow may revert back to only the first port because the tank gas pressure is lower than the cracking pressure.

[0018] When the check valve is in closed mode, the conditions may allow the tank to catch up with evaporation since the first low flow setting is lower than the evaporation rate of the tank. The high flow status may open and close based on the tank and the cracking pressure balance. Should an ice block occur, the tank pressure set point may need to be increased as a tank ages.

[0019] FIG. 1 is a schematic of an embodiment of a freeze protection system 100 for a liquid bulk gas container. The system 100 may include first and second needle valves 102,

104 and an adjustable check valve 106. The first needle valve 102 may be positioned along a first flow path 108 connecting an inlet 110 and an outlet 112. A second flow path 114 may include the adjustable check valve 106 and the second needle valve 104. The second flow path 114 may selectively connect the inlet 110 to the outlet 112.

[0020] The first needle valve 102 may functions as a flow restrictor, or maximum flow restriction, by setting a maximum flow when the inlet pressure is below the tank pressure set point. The first needle valve 102 of an embodiment may include a valve having a thin tapered part to restrict through flow along the first flow path 108. In another respect, the first needle valve 102 may also sets a low pressure flow setting. [0021] The second needle valve 104 may affect operation under normal flow conditions may be used to set a high pressure flow setting. That is, the second needle valve 104 may set a maximum flow for when the inlet pressure is above the tank pressure set point (e.g., under normal operating conditions). The second needle valve 104 of an embodiment may include a valve having a thin tapered part to restrict through flow along the second flow path 114.

[0022] The adjustable check valve 106 may be used to set a low tank pressure set point.

In one implementation, the adjustable check valve 106 may prevent gas from flowing through the second flow path 114 should the pressure at the adjustable check valve 106 drops below a level typically ranging around 125 psi to 200 psi. The adjustable check valve 106 may be adjusted using an adjustment mechanism 120, such as small handle.

[0023] The system 100 may also include a pressure sensor 116 positioned near an inlet to the regulator. The pressure sensor 116 may be positioned upstream to detect a low pressure condition, and for instance, to automatically actuate a solenoid 118. For example, the pressure sensor 116 may detect a pressure of less than 180 psi. This condition may coincide with liquid in the line not being expanded to gas. In response, the solenoid may be closed partially or completely. In another embodiment, output from the pressure sensor 116 may initiate an alarm to a user regarding the detected condition.

[0024] The pressure sensor 116 of another embodiment may also be used to initiate automatically closing an electronically actuated check valve/intemal solenoid (as opposed to the mechanically controlled adjustable check valve 106 of FIG. 1). The pressure sensor 116 and solenoid 118 of an embodiment of the system may be added on to the regulator module 204 as system add-on. In a sense, the regulator module may protect the equipment, while the pressure sensor 116 and the solenoid 118 (and alert system) may provide a preemptive alert a user and provide another layer of protection with or without the regulator. An alert may be used to signal for a manual intervention of the condition .

[0025] FIG. 2 is a block diagram of another embodiment of a freeze protection system 200 that includes a liquid bulk container 202. The system 200 may additionally include a regulator module 204 having an inlet 206 and an outlet 208. The regulator module 204 may include multiple flow paths that selectively connect the inlet 206 to the outlet 208. For instance, a first flow path 210 may include a first valve 212 and associated pressure/flow setting. A second flow path 214 may include a second valve 216 in line with an adjustable cutoff valve 218. Illustrative embodiments of the cutoff valve 218 may include a ball and spring valve or a solenoid. In the case of the latter, the system 200 may include a sensor 226 (shown in dashed lines) to electronically sense and feedback detected pressures or flowrates. Another or the same embodiment may include a flowmeter 224 (shown in dashed lines) to restrict flow over time.

[0026] In the case of a ball and spring assembly, pressure present in the system 200 may mechanically and physically pressure or release the ball and spring without requiring a user. The cutoff valve 218 may be adjustable.

[0027] The container 202 may include an internal evaporator 220, but another embodiment may include an external evaporator 222. Whether the evaporator is positioned within the first flow path may affect the size and cost and other factors.

[0028] As shown in FIG. 2, the system 200 may also include an alert module 234 that may notify a user via a light, buzzer, text, call or other notification system of a low pressure condition. The alert module 234 may be activated by pressure sensors 226. The pressure sensors 226 of one embodiment of the system 200 may be positioned inside of the regulator module 204. Pressure sensors of another embodiment of the system 200 may be externally positioned upstream near the regulator inlet 206. The alert module 234 may additionally be activated in response to an ice detection module 228 determining that ice is present on the surface of the liquid bulk container 202. The sensors 226, 228 may detected a low pressure condition for instance, and automatically actuate a solenoid 118. The pressure sensors 226, 228 may also be used to initiate automatically closing a solenoid 232. In certain embodiments, the solenoid 232 may completely close, while it may partially close in other embodiments of the system 200. [0029] FIG. 3 is a perspective view of an embodiment of a regulator system 300 that includes needle valves 302, 304 and an adjustable check valve 306. The system 300 also includes an inlet valve 308 (now shown) and an outlet valve 310.

[0030] FIG. 4 is a method of manufacturing a freeze protection system for a liquid bulk gas container. An embodiment of the method 400 may include providing first and second pathways at 402. Each pathway may selectively connect an inlet and outlet of a regulator.

The pathways may comprise pipes or other channels that are different lengths and diameters.

[0031] A liquid bulk gas container may be coupled to the inlet at 406. An evaporator may be positioned inside the container.

[0032] A first needle valve may be positioned at 408 along the first pathway connecting the inlet and to the outlet. Flow restrictions may be set at 410 using the first needle valve.

For instance, a user may adjust the needle valve or it may be factory preset at a maximum flow restriction for when the inlet pressure is below the tank pressure set point. The first needle valve may be used to concurrently set a low pressure flow setting at 412.

[0033] The second needle valve may be positioned at 414 along the second pathway. The second needle valve may be used to set a high pressure flow setting at 416 operation under normal flow conditions. That is, the second needle valve may set a maximum flow for when the inlet pressure is above the tank pressure set point.

[0034] An adjustable check valve may also be positioned along the second pathway at 418 to selectively connect the inlet to the outlet. The low tank pressure set point may be set at 420 using the adjustable check valve. The low tank pressure set point may prevent gas from flowing through the second flow path if the pressure at the adjustable check valve drops below a level that could be associated with obstruction due to freezing.

[0035] A pressure sensor may be positioned upstream at 422. The pressure sensor may be similar to the pressure sensor 116 of FIG. 1. The pressure sensor may be configured to sense a low pressure and initiate a remedial action, such as initiate an alarm or close a solenoid. [0036] Such a solenoid may be positioned at 424. The solenoid may be in addition to a check valve or solenoid that internal to a regulator module.

[0037] At 426, a notification system may be included to alert a user if a low pressure or ice condition has been sensed. Illustrative notifications may include a buzzer, light, electronic mail, or text, among other alarm measures.

[0038] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

[0039] In the preceding, reference is made to embodiments presented in this disclosure. However, the scope of the present disclosure is not limited to specific described embodiments. Instead, any combination of the features and elements, whether related to different embodiments or not, is contemplated to implement and practice contemplated embodiments. Furthermore, although embodiments disclosed herein may achieve advantages over other possible solutions or over the prior art, whether or not a particular advantage is achieved by a given embodiment is not limiting of the scope of the present disclosure. Thus, the aspects, features, embodiments and advantages described above are merely illustrative and are not considered elements or limitations of the appended claims except where explicitly recited in a claim(s). Likewise, reference to “the invention” shall not be construed as a generalization of any inventive subject matter disclosed herein and shall not be considered to be an element or limitation of the appended claims except where explicitly recited in a claim(s).

[0040] Aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro- code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.”

[0041] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.