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  Control valve assembly for controlling gas flow in gas combustion systemsUSPTO Application #: 20060057520Title: Control valve assembly for controlling gas flow in gas combustion systems Abstract: A control valve assembly includes an inlet for receiving a gas flow and an outlet for providing the gas flow to a gas burner. The assembly also includes a positive-shutoff valve for interrupting the gas flow from the inlet. A micro electromechanical system (MEMS) valve is coupled in series to the positive-shutoff value between the inlet and the outlet for regulating the gas flow from the inlet to the outlet. (end of abstract) Agent: Patrick S. Yoder Fletcher Yoder - Houston, TX, US Inventors: Richard Joseph Saia, David Joseph Najewicz, Charles Erklin Seeley, Guanghua Wu, Aaron Jay Knobloch USPTO Applicaton #: 20060057520 - Class: 431281000 (USPTO) Related Patent Categories: Combustion, Separately Supplied Or Controlled, Physically Related Flame Holders, E.g., Diverse Fuels, Pilot And Main, Etc., Correlated Controls The Patent Description & Claims data below is from USPTO Patent Application 20060057520. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND [0001] The invention relates generally to gas combustion systems, and more particularly, to control of gas flow in a gas combustion system. [0002] Various gas combustion systems are known and are generally in use. For example, a gas cooking system receives a flammable gas flow from a supply and this flow of gas is directed to a gas burner of the gas cooking system. Downstream combustion components, such as burners, require large cross-sections in the flow circuit to accommodate flow rates that enable high heat output. [0003] In general, the gas cooking system employs a flow control mechanism, such as a manual mechanical valve, for metering the gas flow from the supply to the gas burner. Certain other natural gas combustion systems employ electronic control via solenoid actuated valves to regulate large flows of gas. Such systems employ either a single continuously variable solenoid valve, or a series of on/off solenoid valves to regulate the flow. [0004] Certain other natural gas combustion systems employ a micro electromechanical systems (MEMS) valve for electronic flow control. Such MEMS valves are manufactured by employing batch fabrication processes such as those employed in the integrated circuit industry to fabricate mechanical or coupled electromechanical devices. The use of such MEMS devices is advantageous for improved flow control at lower manufacturing cost. However, designing such systems is challenging due to large actuation displacement requirements that are required for such systems as a large cross section area may be required in the flow circuit to accommodate high levels of flow. Further, it is difficult to achieve large actuation displacements with a small MEMS device. [0005] In systems where MEMS devices are employed for the gas flow control, it may be difficult to package and integrate a small size chip of the MEMS device as a part of a macro scale system. In addition, heat generated by an electrothermal actuator of the MEMS device during actuation may cause device failure. Therefore, it is desirable to transfer the generated heat away from the device. Further, use of electrothermal actuators for flow control requires individual calibration of the electrothermal actuators with supporting electronic feedback control for providing accurate low gas flows. Incorporation of individual calibration of the electrothermal actuators is a challenge due to costs and added complexity involved in such calibration arrangements. [0006] Accordingly, it would be desirable to develop a system for flow control of a liquid or gaseous medium with a positive shutoff seal capability. It would also be advantageous to provide a system that could achieve an accurate low flow control and a high flow control up to a maximum designed flow for such medium. It would also be desirable to provide robust, fluidic and electrical connections for the flow control mechanism for efficient flow control of the liquid or gaseous medium in such system. BRIEF DESCRIPTION [0007] Briefly, in accordance with one aspect of the present invention a control valve assembly includes an inlet for receiving a gas flow and an outlet for providing the gas flow to a gas burner. The assembly also includes a positive-shutoff valve for interrupting the gas flow from the inlet. A micro electromechanical system (MEMS) valve is coupled in series to the positive-shutoff valve between the inlet and the outlet for regulating the gas flow from the inlet to the outlet. [0008] In accordance with another aspect of the present invention a method of controlling a gas flow in a gas combustion system with a gas burner includes receiving the gas flow via an inlet and controlling the gas flow from the inlet by opening and closing a positive-shutoff valve. The method also includes regulating the gas flow from the inlet to the gas burner via a MEMS valve when the positive shutoff valve is open. DRAWINGS [0009] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: [0010] FIG. 1 is a diagrammatical representation of a gas burner system with a control valve assembly for controlling a gas flow to a gas burner in accordance with aspects of the present technique; [0011] FIG. 2 is a diagrammatical representation of an exemplary control valve assembly for a gas combustion system in accordance with aspects of the present technique; [0012] FIG. 3 is an exploded view of the control valve assembly of FIG. 2; [0013] FIG. 4 depicts an exemplary flow path of gas via the control valve assembly of FIG. 2; [0014] FIG. 5 is a graphical representation of exemplary input voltage settings for the control valve assembly of FIG. 2 for a low flow control of gas in accordance with aspects of the present technique; [0015] FIG. 6 is a diagrammatical representation of an exemplary substrate employed to mount MEMS valve dies in accordance with aspects of the present technique; [0016] FIG. 7 is a diagrammatical representation of an exemplary sealing device for the substrate employed to mount the MEMS valve dies of FIG. 6 according to one aspect of the invention; [0017] FIG. 8 is a sectional view of the sealing device of FIG. 7; [0018] FIG. 9 is a diagrammatical representation of an exemplary substrate illustrating sealing features and assembly for the substrate of FIG. 6 according to another aspect of the invention; [0019] FIG. 10 is a diagrammatical representation of an exemplary process for manufacturing of the substrate employed to mount the MEMS valve dies of FIG. 7 according to one aspect of the invention; and [0020] FIG. 11 is a diagrammatical representation of an exemplary process for manufacturing of the substrate employed to mount the MEMS valve dies of FIG. 7 according to another aspect of the invention. 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