Patent Description:
The present invention relates in general to a ball valve having a seat insert configured to provide a fluid tight seal when operated at or subjected to cryogenic temperatures, and more particularly to a ball valve having a seat formed within the valve body that includes a cavity having an angled wall and a seat insert at least partially disposed within the cavity and having a first sealing surface that forms a first sealing interface with the ball to prevent leakage through a first leakage path and a second sealing surface that forms a second sealing interface with the angled wall to prevent leakage through a second leakage path when operated at or subjected to cryogenic temperatures. A spring acting against a fixing plate biases the seat insert against the angled wall, and the angled wall drives or forces the seat insert upwards, thereby increasing a sealing force between the seat insert and the angled wall of the seat to prevent leakage through secondary leakage path when cryogenic temperatures may cause the seat, the seat insert, or combinations thereof to shrink in size.

So that the manner in which the features and advantages of the embodiments are attained and can be understood in more detail, a more particular description may be had by reference to the embodiments thereof that are illustrated in the appended drawings. However, the drawings illustrate only some embodiments and therefore are not to be considered limiting in scope as there may be other equally effective embodiments.

<FIG> shows a partial cross-sectional view of a valve <NUM> according to an embodiment of the disclosure. Valve <NUM> generally comprises a ball valve and comprising a valve body <NUM> having a longitudinal axis <NUM> along a flow path <NUM> through the valve <NUM> and a ball <NUM> selectively rotatable within the valve body <NUM> to selectively allow fluid flow along the flow path <NUM> and through the valve <NUM>. Valve <NUM> also comprises a seat <NUM> comprising a cavity <NUM> formed within the valve body <NUM> and a seat insert <NUM> at least partially disposed within the cavity <NUM>. In some embodiments, the seat insert <NUM> may comprise a complementary profile and/or shape to the cavity <NUM> of the seat <NUM>. Accordingly, it will be appreciated that the seat <NUM> and the seat insert <NUM> are designed to prevent leakage of a fluid through each of a first leakage path (shown as "<NUM>" in <FIG>) and a second leakage path (shown as "<NUM>" in <FIG>) when the ball <NUM> is selectively rotated to prevent fluid flow along the flow path <NUM> and through the valve <NUM>. Additionally, the valve <NUM> also comprises a fixing plate <NUM> and one or more springs <NUM>.

In some embodiments, the cavity <NUM> may comprise a first major surface <NUM> (top), a second major surface <NUM> (bottom) opposite of the first major surface <NUM>, and an angled wall <NUM> disposed between the first major surface <NUM> and the second major surface <NUM>. In some embodiments, the first major surface <NUM> and/or the second major surface <NUM> may be substantially planar. Additionally, in some embodiments, the first major surface <NUM> and the second major surface <NUM> may be substantially parallel. However, in other embodiments, the first major surface <NUM> and/or the second major surface <NUM> may be non-planar.

In some embodiments, the angled wall <NUM> may me substantially planar. In other embodiments, the angled wall <NUM> may be non-planar (e.g., curved). In yet other embodiments, the angled wall <NUM> may comprise any combination of substantially planar and non-planar features. In some embodiments, the angled wall <NUM> may form an angle with the longitudinal axis <NUM> of at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, or at least <NUM> degrees. In some embodiments, the angled wall <NUM> may form an angle with the longitudinal axis <NUM> that is not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, or not greater than <NUM> degrees. Further, it will be appreciated that the angled wall <NUM> may form an angle with the longitudinal axis <NUM> that is between any of these minimum and maximum values, such as at least <NUM> degrees and not greater than <NUM> degrees.

In some embodiments, the seat insert <NUM> may comprise a first major surface <NUM> (top) adjacent to the first major surface <NUM> of the cavity <NUM>, a second major surface <NUM> (bottom) opposite of the first major surface <NUM> and adjacent to the second major surface <NUM> of the cavity <NUM>, a first sealing surface <NUM> disposed between the first major surface <NUM> and the second major surface <NUM> and adjacent to the ball <NUM>, and a second sealing surface <NUM> disposed between the first major surface <NUM> and the second major surface <NUM>, opposite of the first sealing surface <NUM>, and adjacent to the angled wall <NUM>. In some embodiments, the seat insert <NUM> may also comprise an extension <NUM> extending from the first major surface <NUM>. In some embodiments, the first major surface <NUM> and/or the second major surface <NUM> may be substantially planar. Additionally, in some embodiments, the first major surface <NUM> and the second major surface <NUM> may be substantially parallel. However, in other embodiments, the first major surface <NUM> and/or the second major surface <NUM> may be non-planar. In some embodiments, the first sealing surface <NUM> and/or the second sealing surface <NUM> may be substantially planar. However, in other embodiments, the first sealing surface <NUM> and/or the second sealing surface <NUM> may be non-planar (e.g., curved). In yet other embodiments, the first sealing surface <NUM> and/or the second sealing surface <NUM> may comprise any combination of substantially planar and non-planar features.

It will be appreciated that the first sealing surface <NUM> may be designed to form a first sealing interface with the ball <NUM> to prevent leakage through the first leakage path (shown as "<NUM>" in <FIG>), and the second sealing surface <NUM> may be designed to form a second sealing interface with the angled wall <NUM> to prevent leakage through a second leakage path (shown as "<NUM>" in <FIG>) when the ball <NUM> is selectively rotated to prevent fluid flow along the flow path <NUM> and through the valve <NUM>. As such, in some embodiments, the second sealing surface <NUM> may comprise a complementary profile to the angled wall <NUM>, such that in embodiments where the angled wall <NUM> is curved, the second sealing surface <NUM> may be curved, and in embodiments where the angled wall <NUM> is planar, the second sealing surface <NUM> may be curved, planar, or combinations thereof.

The first sealing surface <NUM> and the second sealing surface <NUM> may form a sealing angle. In some embodiments, the sealing angle may be defined as the angle between the first sealing surface <NUM> and the second sealing surface <NUM>. For embodiments having one or more planar sealing surfaces, the sealing angle may be determined using a planar vector of the one or more sealing surfaces. For embodiments having one or more curved sealing surfaces, the sealing angle may be determined using a tangent vector extending from a midpoint of the one or more curved sealing surfaces. In some embodiments, the sealing angle may be at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, or at least <NUM> degrees, at least <NUM> degrees, at least <NUM> degrees, or at least <NUM> degrees. In some embodiments, the sealing angle may be not greater than <NUM> degrees, not greater than <NUM>, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, not greater than <NUM> degrees, or not greater than <NUM> degrees. Further, it will be appreciated that the sealing angle may be between any of these minimum and maximum values, such as at least <NUM> degrees and not greater than <NUM> degrees.

In some embodiments, the first sealing surface <NUM> may form a first sealing angle with the longitudinal axis <NUM>, and the second sealing surface <NUM> may form a second sealing angle with the longitudinal axis <NUM>. In some embodiments, the first sealing angle may be greater than the second sealing angle. In other embodiments, the second sealing angle may be greater than the first sealing angle. In yet other embodiments, the first sealing angle and the second sealing angle may be substantially equal.

In some embodiments, the seat insert <NUM> may be formed from a polymeric material. Accordingly, in some embodiments, the seat insert <NUM> may be formed from PTFE, a fluoropolymer, a perfluoropolymer, PTFE, PVF, PVDF, PCTFE, PFA, FEP, ETFE, ECTFE, PCTFE, a polyarylketone such as PEEK, PEK, or PEKK, a polysulfone such as PPS, PPSU, PSU, PPE, or PPO, aromatic polyamides such as PPA, thermoplastic polyimides such as PEI or TPI, or any combination thereof. Still further, in some embodiments, the seat insert <NUM> may be formed from one or more of the materials listed above that are modified with at least one filler (e.g., fibers).

The fixing plate <NUM> is coupled to and/or integrated with the body <NUM> of the valve <NUM>. The fixing plate <NUM> forms a secondary cavity <NUM> within the cavity <NUM> of the seat <NUM>. One or more springs <NUM> (formed from titanium, stainless steel, carbon steel, other alloys, or combinations thereof) are disposed within the secondary cavity <NUM>. In the embodiment shown, the spring <NUM> may comprise a standalone compression spring and be disposed within the secondary cavity <NUM> between the extension <NUM> of the seat insert <NUM> and the fixing plate <NUM>. As such, the spring <NUM> biases the extension <NUM> of the seat insert <NUM> against the fixing plate <NUM>, thereby forcing the seat insert <NUM> towards the angled wall <NUM> and forcing the second sealing interface <NUM> into contact with the angled wall <NUM>. In turn, the angled wall <NUM> forces the seat insert <NUM> upwards, thereby forcing the first major surface <NUM> of the seat insert <NUM> into contact with the first major surface <NUM> of the cavity <NUM> of the seat <NUM>. The resulting contact thereby operates to substantially reduce and/or prevent leakage through the secondary leakage path.

In some embodiments, as compared to a traditional valve without an angled sealing interface, the angled wall <NUM> may increase a sealing force between the seat insert <NUM> and the seat <NUM> when cryogenic temperature conditions cause the seat insert <NUM> to shrink in size, deform, or otherwise change in profile or shape. In some embodiments, the angled wall <NUM> may increase the sealing force between the seat insert <NUM> and the seat <NUM> by at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>%. In some embodiments, the angled wall <NUM> may increase the sealing force between the seat insert <NUM> and the seat <NUM> by not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, or not greater than <NUM>%. Further, it will be appreciated that the angled wall <NUM> may increase the sealing force between any of these minimum and maximum values, such as at least <NUM>% and not greater than <NUM>%.

<FIG> shows a partial cross-sectional view of a valve <NUM> according to an embodiment of the disclosure. Valve <NUM>, and components thereof, may be substantially similar to valve <NUM>. Valve <NUM> may comprise a ball valve and comprise a valve body <NUM> having a longitudinal axis <NUM> along a flow path <NUM> through the valve <NUM>, a ball <NUM> selectively rotatable within the valve body <NUM> to selectively allow fluid flow along the flow path <NUM> and through the valve <NUM>, a seat <NUM> comprising a cavity <NUM> (having a first major surface <NUM>, a second major surface <NUM>, and an angled wall <NUM>) formed within the valve body <NUM>, a seat insert <NUM> (having a first major surface <NUM>, a second major surface <NUM>, a first sealing surface <NUM>, a second sealing surface <NUM>, and an extension <NUM>) at least partially disposed within the cavity <NUM>, a fixing plate <NUM> that forms a secondary cavity <NUM>, and one or more springs <NUM>. However, in the embodiment shown, the spring <NUM> is integrated into the extension <NUM> of the seat insert <NUM>.

The extension <NUM> may generally comprise a cavity <NUM>. In some embodiments, the cavity <NUM> may comprise a U-shaped cavity formed between a pair of legs <NUM>, <NUM>. However, in other embodiments, the cavity <NUM> may comprise a rectangular-shaped cavity, a V-shaped cavity, or other-shaped cavity formed between the pair of legs <NUM>, <NUM>. One or more springs <NUM> (formed from titanium, stainless steel, carbon steel, or combinations thereof) may generally be disposed within the U-shaped cavity <NUM>. In the embodiment shown, the spring <NUM> may comprise a U-shaped compression spring and be disposed within the U-shaped cavity <NUM> between the pair of legs <NUM>, <NUM>. However, in other embodiments, the spring <NUM> may comprise any other profile and/or shape that is complementary to the cavity <NUM>. It will be appreciated that the extension <NUM> (with legs <NUM>, <NUM>) and/or the spring <NUM> may comprise an interference fit in the secondary cavity <NUM>. As such, the spring <NUM> may bias the first leg <NUM> against the fixing plate <NUM> and bias the second leg <NUM> against an inner wall of the secondary cavity <NUM>, thereby forcing the seat insert <NUM> towards the angled wall <NUM> and forcing the second sealing interface <NUM> into contact with the angled wall <NUM>. In turn, the angled wall <NUM> forces the seat insert <NUM> upwards, thereby forcing the first major surface <NUM> of the seat insert <NUM> into contact with the first major surface <NUM> of the cavity <NUM> of the seat <NUM>. The resulting contact thereby operates to substantially reduce and/or prevent leakage through the secondary leakage path, while preventing leakage through the primary leakage path.

Similarly to the angled wall <NUM> of valve <NUM>, the angled wall <NUM> of valve <NUM> may increase a sealing force between the seat insert <NUM> and the seat <NUM> when cryogenic temperature conditions cause the seat insert <NUM> to shrink in size, deform, or otherwise change in profile or shape. In some embodiments, the angled wall <NUM> may increase the sealing force between the seat insert <NUM> and the seat <NUM> by at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>%. In some embodiments, the angled wall <NUM> may increase the sealing force between the seat insert <NUM> and the seat <NUM> by not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, not greater than <NUM>%, or not greater than <NUM>%. Further, it will be appreciated that the angled wall <NUM> may increase the sealing force between any of these minimum and maximum values, such as at least <NUM>% and not greater than <NUM>%.

<FIG> shows a flowchart of a method <NUM> of preventing leakage in a valve <NUM>, <NUM> according to an embodiment of the disclosure. The method <NUM> may begin at block <NUM> by providing a valve <NUM>, <NUM> comprising a valve body <NUM>, <NUM>, a ball <NUM>, <NUM> selectively rotatable within the valve <NUM>, <NUM>, a seat <NUM>, <NUM> formed within the valve body <NUM>, <NUM> and comprising a cavity having an angled wall <NUM>, <NUM>, and a seat insert <NUM>, <NUM> at least partially disposed within the cavity <NUM>, <NUM> and having a first sealing surface <NUM>, <NUM> and a second sealing surface <NUM>, <NUM>. Method <NUM> may continue at block <NUM> by operating the valve <NUM>, <NUM> in cryogenic temperature conditions. Method <NUM> may continue at block <NUM> by selectively rotating the ball <NUM>, <NUM> to prevent fluid flow along a flow path <NUM>, <NUM> through the valve <NUM>, <NUM>. Method <NUM> may continue at block <NUM> by forming and/or maintaining a first sealing interface between the first sealing surface <NUM>, <NUM> of the seat insert <NUM>, <NUM> and the ball <NUM>, <NUM> to prevent leakage through a first leakage path (shown as "<NUM>" in <FIG> and <FIG>) and simultaneously forming and/or maintaining a second sealing interface between the second sealing surface <NUM>, <NUM> and the angled wall <NUM>, <NUM> to prevent leakage through a second leakage path (shown as "<NUM>" in <FIG> and <FIG>) while the ball <NUM>, <NUM> is selectively rotated to prevent fluid flow along the flow path <NUM>, <NUM> through the valve <NUM>, <NUM>.

This written description uses examples to disclose the embodiments, including the best mode, and also to enable those of ordinary skill in the art to make and use the invention. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

In the foregoing specification, the concepts have been described with reference to specific embodiments. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of invention.

For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus.

Also, the use of "a" or "an" are employed to describe elements and components described herein. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Claim 1:
A valve (<NUM>, <NUM>), comprising:
a valve body (<NUM>, <NUM>);
a ball (<NUM>, <NUM>) selectively rotatable within the valve body (<NUM>, <NUM>);
a seat (<NUM>, <NUM>) formed within the valve body (<NUM>, <NUM>) and comprising a cavity (<NUM>, <NUM>) having an angled wall (<NUM>, <NUM>); and
a seat insert (<NUM>, <NUM>) at least partially disposed within the cavity (<NUM>, <NUM>) and having a first sealing surface (<NUM>, <NUM>) that forms a first sealing interface with the ball (<NUM>, <NUM>) to prevent leakage through a first leakage path and a second sealing surface (<NUM>, <NUM>) that forms a second sealing interface with the angled wall (<NUM>, <NUM>) to prevent leakage through a second leakage path,
characterized in that the valve body (<NUM>, <NUM>) comprises a fixing plate (<NUM>, <NUM>) forming a secondary cavity (<NUM>, <NUM>) within the cavity (<NUM>, <NUM>) of the seat (<NUM>, <NUM>), and in that the valve further comprises a spring (<NUM>, <NUM>) disposed within the secondary cavity (<NUM>, <NUM>) and configured to bias the seat insert (<NUM>, <NUM>) against the angled wall (<NUM>, <NUM>).