Dynamic metal seal

Abstract

Systems and methods include providing a ring seal for a component. The seal includes a metallic ring body including an inner seal leg having a first seal lip, a second seal lip, and a valley disposed between the first seal lip and the second seal lip. The valley includes a plating reservation such that a plating thickness in the valley is greater than a plating thickness on the first seal lip and the second seal lip.

Description

BACKGROUND

[0001] Seals are used in many industrial applications to prevent leakage between components of an assembly. In some applications, the seals can be subjected to extreme operating conditions, such as extreme pressure or temperature. To perform reliably under these extreme operating conditions, a seal stack having multiple seals axially stacked in the assembly can be used to provide redundancy in the seals. The seals in the seal stack can be sequentially pressurized so that when the outermost pressurized seal wears and subsequently fails, the next seal is pressurized before it wears and eventually fails. Such seal stacks have a relatively short life cycle, sometimes less than 200 cycles, and are of high economic cost due to the large footprint of the seal stack and the large area requirement of each seal, requiring precision machining and finishing to mate with the components of the assembly. Accordingly, there is a continuing need in the industry to improve sealing technology for such applications. BRIEF DESCRIPTION OF DRAWINGS

[0002] For a more complete understanding of the manner in which the features and advantages of the implementation are realized, reference is made to the

[0003] Figure 1 is a partial cross-sectional view of an assembly having a seal according to another embodiment of the present disclosure.

[0004] Figure 2 is a partial cross-sectional view of an assembly having a seal according to another embodiment of the present disclosure.

[0005] Figure 3 is a partial cross-sectional view of an assembly having a seal according to another embodiment of the present disclosure.

[0006] Figure 4 is a partial cross-sectional view of an assembly having a seal according to another embodiment of the present disclosure.

[0007] The use of the same reference symbols in different drawings indicates similar or identical items. DETAILED DESCRIPTION

[0008] Figure 1A partial cross-sectional view of an assembly 100 having a seal 150 according to embodiments of the present disclosure is shown. In some embodiments, the assembly 100 can be a valve assembly. In more particular embodiments, the assembly 100 can be a solenoid assembly. In a number of more particular embodiments, the assembly 100 can be a subsea valve, a subsea coupling, or a subsea solenoid assembly. In other embodiments, the assembly 100 can include an automotive component assembly. In particular embodiments, the assembly 100 can include an automotive exhaust assembly. The assembly 100 can generally include a first component (e.g., a housing or inner tube) 102 and a second component (e.g., a shaft or outer tube) 104, which can rotate, oscillate, move laterally, vibrate, remain stationary, or any combination thereof, within the housing about an axis 106. The assembly 100 can also include a cavity 108 formed within the housing 102. In some embodiments, the housing 102 can include a radially inner surface 110 and an axially inner surface 112, which together with the shaft 104 define the cavity 108.

[0009] The annular seal 150 can generally be disposed within the cavity 108 and around the shaft 104 and / or axis 106 of the assembly 100. In some embodiments, the seal 150 can include an interference fit between the axially inner surface 112 of the housing 102 and the shaft 104. The seal 200 can be configured to contact and provide a radial seal between the housing 102 and the shaft 104 of the assembly 100. The seal 150 can generally include a metallic annular body including an inner diameter (ID), an outer diameter (OD), a radial width (RW) defined as the difference between the ID and the OD of the seal 150, and an axial length (AL). In some embodiments, the seal 150 can include a substantially E-shaped cross-sectional profile having a central body portion 152, an inner seal leg 154 extending from the central body portion 152, and an outer seal leg 156 extending from the central body portion 156.

[0010] The central body portion 152 can be in contact with the radially inner surface 110 of the cavity 108 of the housing 102 of the assembly 100. In some embodiments, the central body portion 152 can include opposing arcuate convolutions including a central arcuate portion 158, opposing inner arcuate portions 160 extending inwardly from the central arcuate portion 158 toward the shaft 104, and opposing outer arcuate portions 162 extending outwardly from the central arcuate portion 158 toward the housing 102 of the assembly 100. In some embodiments, the inner arcuate portions 160 and the outer arcuate portions 162 can be in contact with the radially inner surface 110 of the cavity 108 of the housing 102 of the assembly 100. Further, in some embodiments, the central body portion 152 can include a plating.

[0011] The inner seal leg 154 can generally extend inwardly from the inner arc portion 160 of the center body portion 152 and toward the shaft 104 of the assembly 100. The inner seal leg 154 can include a first seal lip 164, a second seal lip 166, and a valley 168 disposed between the first seal lip 164 and the second seal lip 166. In some embodiments, the first seal lip 164 and the second seal lip 166 can be disposed about the ID of the metallic annular body of the seal 150 such that the first seal lip 164 and the second seal lip 166 define the ID of the seal 150. As such, the first seal lip 164 and the second seal lip 166 can form a ridge about the ID of the metallic annular body of the seal 150. The first seal lip 164 and the second seal lip 166 can be in contact with the shaft 104 to form a radial seal with the shaft 104. Additionally, in some embodiments, a plating layer can be disposed over the first seal lip 164 and the second seal lip 166.

[0012] The valley 168 can generally be disposed between the first seal lip 164 and the second seal lip 166. The valley 168 can include an opposing arcuate convolution relative to the first seal lip 164 and the second seal lip 166. In some embodiments, a plating layer can be disposed within the valley 168. In some embodiments, the valley 168 can include a plating layer thickness that is greater than the plating layer thickness on the first seal lip 164 and the second seal lip 166. As such, the seal 150 can include a variable plating layer thickness. In some embodiments, the valley 168 can include a plating reserve 170. In some embodiments, the plating reserve 170 can substantially fill the valley 168 to form a flat seal surface 172. In some embodiments, the flat seal surface 172 can be disposed about the ID of the metallic annular body of the seal 150 such that the flat seal surface 172, along with the first seal lip 164 and the second seal lip 166, define the ID of the seal 150. Collectively, the first seal lip 164, the second seal lip 166, and the flat seal surface 172 can define a contact area about the ID of the seal 150. In some embodiments, the flat seal surface 172 can be substantially parallel to the axis 106 of the shaft 104, orthogonal to the RW of the seal 150, or a combination thereof. Furthermore, in some embodiments, the flat seal surface 172 can be in contact with the shaft 104 and form a radial seal with the shaft.

[0013] The outer seal leg 156 can generally be substantially similar to the inner seal leg 154. In some embodiments, the outer seal leg 156 can be substantially symmetrical with the inner seal leg 154. The outer seal leg 156 can generally extend outward from the outer arcuate portion 162 of the center body portion 152 and toward the housing 102 of the assembly 100. The outer seal leg 156 can include a first seal lip 174, a second seal lip 176, and a valley 178 disposed between the first seal lip 174 and the second seal lip 176. In some embodiments, the first seal lip 174 and the second seal lip 176 can be disposed about the OD of the metallic annular body of the seal 150 such that the first seal lip 174 and the second seal lip 176 define the OD of the seal 150. As such, the first seal lip 174 and the second seal lip 176 can form a ridge about the OD of the metallic annular body of the seal 150. The first seal lip 174 and the second seal lip 176 can be in contact with the axially inner surface 112 of the housing 102 to form a radial seal with the housing 102. Additionally, in some embodiments, a plating layer can be disposed over the first seal lip 174 and the second seal lip 176.

[0014] The valley 178 can generally be disposed between the first seal lip 174 and the second seal lip 176. The valley 178 can include an opposing arcuate convolution relative to the first seal lip 174 and the second seal lip 176. In some embodiments, a plating layer can be disposed within the valley 178. In some embodiments, the valley 178 can include a plating layer thickness that is greater than the plating layer thickness on the first seal lip 174 and the second seal lip 176. As such, the seal 150 can include a variable plating layer thickness. In some embodiments, the valley 178 can include a plating reserve 180. In some embodiments, the plating reserve 180 can substantially fill the valley 178 to form a flat seal surface 182. In some embodiments, the flat seal surface 182 can be disposed about the OD of the metallic annular body of the seal 150 such that the flat seal surface 182, along with the first seal lip 174 and the second seal lip 176, define the OD of the seal 150. Collectively, the first seal lip 174, the second seal lip 176, and the flat seal surface 182 can define a contact area about the OD of the seal 150. In some embodiments, the flat seal surface 182 can be substantially parallel to the axially inner surface 112 of the housing 102, orthogonal to the RW of the seal 150, or a combination thereof. Further, in some embodiments, the flat seal surface 182 can be in contact with and form a radial seal with the axially inner surface 112 of the housing 102.

[0015] The metallic annular body of the seal 150 can generally be formed of an elastic metallic material. More specifically, the metallic annular body of the seal 150 can be formed of a nickel-chromium based alloy, such as nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, copper, magnesium, tin, platinum, lead, iron, or bronze. In some embodiments, the metallic annular body of the seal 150 can include a coating or plating. In some embodiments, the first and second sealing lips 164, 174, 166, 176 of the metallic annular body of the seal 150 can include a plating substantially similar to the plating reserve 170, 180 of the seal 150. In some embodiments, the first and second sealing lips 164, 174, 166, 176 of the metallic annular body of the seal 150 can include a coating or plating formed of a different material than the plating reserve 170, 180 of the seal 150. More specifically, in some embodiments, the coating or plating can include a gold plating, a silver plating, an aluminum chromium nitride (AlCrN) plating, a titanium aluminum nitride (TiAlN) plating, any other wear resistant metal plating, or any combination thereof. Further, in some embodiments, some portions of the metallic annular body of the seal 150 can not include a coating or plating. For example, in some embodiments, the sealing lips 164, 166, 174, 176 can be free of plating such that the plating is only present in the valleys 158, 168 to form the plating reserve 170, 180 and the flat sealing surfaces 172, 182.

[0016] In some embodiments, the plating reserve 170, 180 that can substantially fill the valleys 168, 178 to form the flat sealing surfaces 172, 182 can include an injection molded or compression molded polymer. In some embodiments, the polymer can be a fluoropolymer, a perfluoropolymer, PTFE, PVF, PVDF, PCTFE, PFA, FEP, ETFE, ECTFE, PCTFE, a fluorinated copolymer, a polyaryletherketone such as PEEK, PK, PEK, PEKK, PEKEKK, a polysulfone such as PPS, PPSU, PSU, a polyether such as PPE or PPO, an aromatic polyamide such as PPA or an aliphatic polyamide such as PA, a thermoplastic polyimide such as PEI or TPI, a thermoplastic elastomer such as TPE, a thermoplastic vulcanizate such as TPV, a thermoplastic olefin such as TPO, Teflon, or any other polymer. In some embodiments, the polymer can include one or more fillers. In some embodiments, the fillers can include carbon, graphite, graphene, mica, vermiculite, titanium dioxide (TiO2), molybdenum disulfide (MoS2), tungsten disulfide (WS2), barium sulfate (BaSO4), talc, mica, boron nitride (BN), an aromatic polyester, an inorganic filler, a combination thereof, or any other suitable filler. In some embodiments, the fillers can be configured to provide joint lubrication. In some embodiments, the fillers can be configured to expand to fill voids left by worn or degraded polymer to continue to provide an effective fluid-tight seal after the polymer is worn or degraded.

[0017] Collectively, the first seal lip 164, the second seal lip 166, and the flat sealing surface 172 of the inner seal leg 154 can define a contact area around the ID of the seal 150, while the first seal lip 174, the second seal lip 176, and the flat sealing surface 182 of the outer seal leg 156 can define a contact area around the OD of the seal 150. The seal lips 164, 166 can provide redundancy for the radial seal between the shaft 104 and the inner seal leg 154, while the seal lips 174, 176 can provide redundancy for the radial seal between the housing 102 and the outer seal leg 156. Additionally, in some embodiments, the greater plating thickness in the valleys 168, 178 forming the flat sealing surfaces 172, 182 can also provide redundancy for the radial seal between the housing 102 and the shaft 104.

[0018] In operation, the plating on the seal lips 164, 166, 174, 176 (or the seal lips 164, 166, 174, 176 in embodiments having un-plated seal lips) can wear due to friction between the components 102, 104 of the assembly 100 and the seal 150. The plating reserve 170, 180 can also wear with the plating on the seal lips 164, 166, 174, 176 (or the seal lips 164, 166, 174, 176 in embodiments having un-plated seal lips), thereby exposing the new plating material in the plating reserve 170, 180. In cases where a conventional seal can fail when such a seal experiences significant wear, the plating reserve 170, 180 in the valleys 168, 178 forming the flat sealing surfaces 172, 182 can continuously provide a radial seal between the housing 102 and the shaft 104. Thus, in some embodiments, the plating reserve 170, 180 can extend the life of the seal 150 and / or can prevent catastrophic failure of the seal 150 in the assembly 100.

[0019] In some embodiments, the plating thickness at the first sealing lip 164, 174, the second sealing lip 166, 176, and / or the valley 168, 178 (forming the plating reserve 170, 180 in the valley 168, 178 forming the flat sealing surface 172, 182) can include a beneficial thickness that can extend the life of the seal 150 and / or prevent catastrophic failure of the seal 150 in the assembly 100. In some embodiments, the plating thickness at the first sealing lip 164, 174 and the second sealing lip 166, 176 of the first sealing leg 154 and / or the second sealing leg 156 can be at least 0.0005 mm, at least 0.005 mm, at least 0.01 mm, at least 0.02 mm, at least 0.025 mm, at least 0.03 mm, at least 0.04 mm, at least 0.05 mm, at least 0.10 mm, at least 0.15 mm, at least 0.20 mm, at least 0.25 mm, or at least 0.30 mm. In some embodiments, the plating thickness at the first sealing lip 164, 174 and the second sealing lip 166, 176 of the first sealing leg 154 and / or the second sealing leg 156 can be no greater than 1.0 mm, no greater than 0.75 mm, no greater than 0.70 mm, no greater than 0.65 mm, no greater than 0.60 mm, no greater than 0.55 mm, no greater than 0.50 mm, no greater than 0.45 mm, no greater than 0.40 mm, no greater than 0.35 mm, no greater than 0.30 mm, no greater than 0.25 mm, or no greater than 0.015 mm. Further, it should be appreciated that the plating thickness at the first sealing lip 164, 174 and the second sealing lip 166, 176 of the first sealing leg 154 and / or the second sealing leg 156 can be between any of these minimum and maximum values, such as at least 0.0005 mm to no greater than 1.0 mm, or even at least 0.005 mm to no greater than 0.015 mm.

[0020] In some embodiments, the plating thickness at the valleys 168, 178 of the first and / or second seal leg 154, 156 can be at least 0.005 mm, at least 0.01 mm, at least 0.015 mm, at least 0.02 mm, at least 0.025 mm, at least 0.03 mm, at least 0.04 mm, at least 0.05 mm, at least 0.10 mm, at least 0.15 mm, at least 0.20 mm, at least 0.25 mm, or at least 0.30 mm. In some embodiments, the plating thickness at the valleys 168, 178 of the first and / or second seal leg 154, 156 can be no greater than 1.0 mm, no greater than 0.75 mm, no greater than 0.70 mm, no greater than 0.65 mm, no greater than 0.60 mm, no greater than 0.55 mm, no greater than 0.50 mm, no greater than 0.45 mm, no greater than 0.40 mm, no greater than 0.35 mm, no greater than 0.30 mm, no greater than 0.25 mm, no greater than 0.05 mm, or no greater than 0.025 mm. Further, it will be appreciated that the plating thickness at the valleys 168, 178 of the first and / or second seal leg 154, 156 can be between any of these minimum and maximum values, such as at least 0.005 mm to no greater than 1.0 mm, or even at least 0.015 mm to no greater than 0.05 mm.

[0021] In some embodiments, the plating thickness at the valleys 168, 178 of the first and / or second seal leg 154, 156 can be at least 1.05 times, at least 1.10 times, at least 1.15 times, at least 1.25 times, at least 1.5 times, at least 1.75 times, at least 2.0 times, at least 2.5 times, or at least 3.0 times thicker than the plating thickness at the first and second seal lips 164, 174 and 166, 176 of the first and / or second seal leg 154, 156. In some embodiments, the plating thickness at the valleys 168, 178 of the first and / or second seal leg 154, 156 can be no greater than 10.0 times, no greater than 9.0 times, no greater than 8.0 times, no greater than 7.0 times, no greater than 6.0 times, no greater than 5.0 times, no greater than 4.5 times, no greater than 4.0 times, no greater than 3.5 times, or no greater than 3 times thicker than the plating thickness at the first and second seal lips 164, 174 and 166, 176 of the first and / or second seal leg 154, 156. Further, the plating thickness at the valleys 168, 178 of the first and / or second seal leg 154, 156 can be between any of these minimum and maximum values, such as at least 1.05 times to no greater than 10 times, or even at least 1.25 times to no greater than 3 times thicker than the plating thickness at the first and second seal lips 164, 174 and 166, 176 of the first and / or second seal leg 154, 156.

[0022] In some example embodiments, the first and / or second seal lips 164, 174, 166, 176 of the first and / or second seal legs 154, 156 can not include a plating thickness, while the plating thickness at the valleys 168, 178 of the first and / or second seal legs 154, 156 can be 0.0762 mm. In some example embodiments, the plating thickness at the first and / or second seal lips 164, 174, 166, 176 of the first and / or second seal legs 154, 156 can be 0.0381 mm, while the plating thickness at the valleys 168, 178 of the first and / or second seal legs 154, 156 can be 0.0762 mm. In other example embodiments, the plating thickness at the first and / or second seal lips 164, 174, 166, 176 of the first and / or second seal legs 154, 156 can be 0.0381 mm, while the plating thickness at the valleys 168, 178 of the first and / or second seal legs 154, 156 can be 0.1143 mm.

[0023] In some embodiments, the seal 150 can be optimized for a particular assembly 100. In some embodiments, a contact length (CL) along an axial direction of the seal 150 can be proportional to a torque rating of the shaft 104 of the assembly 100. Accordingly, in some embodiments, the flat seal surface 172, 182 of the inner and / or outer seal leg 154, 156 can include a CL that is at least 1%, at least 2%, at least 3%, at least 4%, at least 5%, at least 10%, at least 15%, at least 20%, or at least 25% of an axial length (AL) of a metal annular body of the seal 150. In some embodiments, the flat seal surface 172, 182 of the inner and / or outer seal leg 154, 156 can include a CL that is not greater than 95%, not greater than 90%, not greater than 85%, not greater than 80%, not greater than 75%, not greater than 50%, or not greater than 25% of the AL of the metal annular body of the seal 150. Further, it should be appreciated that the flat seal surface 172, 182 of the inner and / or outer seal leg 154, 156 can include a CL between any of these minimum and maximum values, such as at least 1% to not greater than 95%, or even at least 5% to not greater than 25% of the AL of the metal annular body of the seal 150.

[0024] Figure 2A partial cross-sectional view of an assembly 100 having a seal 250 is shown in accordance with another embodiment of the present disclosure. In some embodiments, the seal 250 can be substantially similar to the seal 150. However, the seal 250 can include an annular energizing element 270. The energizing element 270 can be disposed between the valleys 168, 178 and in contact with the inner surfaces 184, 186 of the valleys 168, 178 of each of the first and / or second seal legs 154, 156. In some embodiments, the energizing element 270 can also be in contact with the inner surface 188 of the central arcuate portion 158 of the central body portion 152 of the seal 150. Accordingly, in some embodiments, the energizing element 270 can be configured to bias the inner and outer seal legs 152, 154 away from each other. In some embodiments, the energizing element 270 can include a circular profile. However, in other embodiments, the energizing element 270 can include another profile, such as an elliptical profile, a U-shaped profile, a V-shaped profile, a C-shaped profile, or any other shaped profile. In some embodiments, the energizing element 270 can include a single layer of material. However, in other embodiments, the energizing element 270 can include multiple layers or pieces of material. Suitable materials for the energizing element 270 can include, for example, nickel-chromium based alloys, such as nickel-based alloys, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, copper, magnesium, tin, platinum, lead, iron, bronze, other elastic metallic materials, or any combination thereof.

[0025] Figure 3is a partial cross-sectional view of an assembly 100 having a seal 350 according to another embodiment of the present disclosure. In some embodiments, the seal 350 can be substantially similar to the seal 150. The seal 350 includes a central body portion 352, an inner seal leg 354 extending from the central body portion 352, and an outer seal leg 356 extending from the central body portion 352. The inner seal leg 354 can include a first seal lip 364, a second seal lip 366, and a valley 368 disposed between the first seal lip 364 and the second seal lip 366. In some embodiments, a plating layer can be disposed within the valley 368 according to the embodiments disclosed herein. In some embodiments, the valley 368 can include a plating layer thickness that is greater than the plating layer thickness on the first seal lip 364 and the second seal lip 366. As such, the seal 350 can include a variable plating layer thickness. In some embodiments, the valley 368 can include a plating reserve 370 according to the embodiments disclosed herein. In some embodiments, the plating reserve 370 can substantially fill the valley 368 to form a flat seal surface 372. However, in contrast to the substantially E-shaped cross-sectional profile of the seal 150, the seal 350 can include a substantially C-shaped or J-shaped cross-sectional profile. As such, in some embodiments, the central body portion 352 of the seal 350 can be arcuate. Additionally, in some embodiments, the outer seal leg 356 can also be arcuate. Further, in alternative embodiments, the inner seal leg 354 and the outer seal leg 356 can be reversed such that the inner seal leg 354 can be arcuate and the outer seal leg 356 includes a first seal lip 364, a second seal lip 366, and a valley 368 disposed between the first seal lip 364 and the second seal lip 366.

[0026] Figure 4is a partial cross-sectional view of an assembly 100 having a seal 450 according to another embodiment of the disclosure. In some embodiments, the seal 450 can be substantially similar to the seal 150. The seal 450 includes a central body portion 452, an inner seal leg 454 extending from the central body portion 452, and an outer seal leg 456 extending from the central body portion 452. The inner seal leg 454 can include a first seal lip 464, a second seal lip 466, and a valley 468 disposed between the first seal lip 464 and the second seal lip 466. In some embodiments, a plating layer can be disposed within the valley 468 according to the embodiments disclosed herein. In some embodiments, the valley 468 can include a plating layer thickness that is greater than the plating layer thickness on the first seal lip 464 and the second seal lip 466. As such, the seal 450 can include a variable plating layer thickness. In some embodiments, the valley 468 can include a plating reserve 470 according to the embodiments disclosed herein. In some embodiments, the plating reserve 470 can substantially fill the valley 468 to form a flat seal surface 472. However, in contrast to the substantially E-shaped cross-sectional profile of the seal 150, the central body portion 452 of the seal 450 can be arcuate, while the outer seal leg 456 can be linear or planar, such that the outer seal leg 456 can be substantially parallel to the housing 102 and / or the shaft 104. Further, in alternative embodiments, the inner seal leg 454 and the outer seal leg 456 can be reversed, such that the inner seal leg 454 can be linear or planar, and the outer seal leg 456 includes a first seal lip 464, a second seal lip 466, and a valley 468 disposed between the first seal lip 464 and the second seal lip 466.

[0027] Other embodiments of the seals 150, 250, 350, 450 can include a substantially U-shaped cross-sectional profile, a substantially D-shaped cross-sectional profile, a substantially parabolic cross-sectional profile, a substantially elliptical cross-sectional profile, or any other shaped cross-sectional profile. In some embodiments, it should be understood that the assembly 100 can include one or more seals 150, 250, 350, 450. In some embodiments, one or more of the seal legs 154, 156, 354, 454 can include additional seal lips 164, 166, 174, 176, 364, 366, 464, 466 to form multiple valleys 168, 178, 368, 468 in the seal 150, 250, 350, 450. The multiple valleys 168, 178, 368, 468 can be configured according to the embodiments herein such that each of the multiple valleys 168, 178, 368, 468 includes a plating reserve 170, 180, 370, 470 that forms multiple flat seal surfaces 172, 182, 372, 472 in one or more of the seal legs 154, 156, 354, 454.

[0028] Embodiments of the seal 150, 250, 350, 450 can include any size suitable for a particular application. In some embodiments, the inner diameter of the metallic annular body of the seal 150, 250, 350, 450 can be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, at least 25 mm, at least 50 mm, at least 75 mm, at least 100 mm, at least 150 mm, at least 200 mm, at least 250 mm, at least 300 mm, or even larger. In some embodiments, the outer diameter of the metallic annular body of the seal 150, 250, 350, 450 can be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, at least 11 mm, at least 12 mm, at least 13 mm, at least 14 mm, at least 15 mm, at least 25 mm, at least 50 mm, at least 75 mm, at least 100 mm, at least 150 mm, at least 200 mm, at least 250 mm, at least 300 mm, at least 500 mm, or even larger.

[0029] Further, in some embodiments, embodiments of the seal 150, 250, 350, 450 can allow for a leak of no greater than 0.25 cubic centimeters per minute (cc / min), no greater than 0.15 cc / min, no greater than 0.10 cc / min, no greater than 0.075 cc / min, no greater than 0.050 cc / min, no greater than 0.040 cc / min, no greater than 0.030 c / min, no greater than 0.025 cc / min, no greater than 0.020 cc / min, no greater than 0.015 cc / min, no greater than 0.010 cc / min, or no greater than 0.005 cc / min. In some embodiments, embodiments of the seal 150, 250, 350, 450 can allow for these amounts of leakage at a pressure of at least 5 pounds per square inch (psi) (34.47 kPa), at least 10 psi (68.94 kPa), at least 15 psi (103.42 kPa), at least 20 psi (137.89 kPa), at least 25 psi (172.36 kPa), at least 30 psi (206.84 kPa), or at least 35 psi (241.31 kPa). Further, in some embodiments, embodiments of the seal 150, 250, 350, 450 can allow for these amounts of leakage at a minimum temperature of at least 15 degrees Celsius, at least 20 degrees Celsius, at least 25 degrees Celsius, at least 30 degrees Celsius, at least 35 degrees Celsius, at least 40 degrees Celsius, or at least 45 degrees Celsius at the listed pressures. For example, one exemplary embodiment of the seal 150, 250, 350, 450 achieves a leak rate of about 0.040 cc / min at 25 psi (172.36 kPa) at room temperature with a minimum interference of 0.002 inches (0.050 mm) between the seal 150, 250, 350, 450 and components 102, 104 of the assembly 100.

[0030] Embodiments of the assembly 100 and / or the seal 150, 250, 350, 450 can include one or more of the following embodiments:

[0031] Embodiment 1. A seal, comprising: a metallic annular body comprising an inner sealing leg comprising a first sealing lip, a second sealing lip, and a valley disposed between the first sealing lip and the second sealing lip, wherein the valley comprises a plating reservation having a plating thickness that is greater than a plating thickness on the first sealing lip and the second sealing lip.

[0032] Embodiment 2. An assembly comprising: a shaft having a shaft axis; a housing comprising a cavity and annularly disposed about the shaft; and a seal disposed within the cavity and configured to provide a radial seal between the shaft and the housing, the seal comprising: a metallic annular body comprising an inner seal leg in contact with the shaft, wherein the inner seal leg comprises a first seal lip, a second seal lip, and a valley disposed between the first seal lip and the second seal lip, and wherein the valley comprises a plating reservation having a plating thickness that is greater than a plating thickness on the first seal lip and the second seal lip.

[0033] Embodiment 3. The seal or assembly of any one of embodiments 1-2, wherein the metallic annular body comprises a central body portion.

[0034] Embodiment 4. The seal or assembly of embodiment 3, wherein the central body portion is arcuate.

[0035] Embodiment 5. The seal or assembly of embodiment 3, wherein the central body portion comprises a plurality of opposing arcuate convolutions.

[0036] Embodiment 6. The seal or assembly of any one of embodiments 3-5, wherein the inner seal leg extends from the central body portion.

[0037] Embodiment 7. The seal or assembly of any one of embodiments 1-6, wherein the metallic annular body comprises an outer seal leg.

[0038] Embodiment 8. The seal or assembly of embodiment 7, wherein the outer seal leg extends from the central body portion.

[0039] Embodiment 9. The seal or assembly of any one of embodiments 7-8, wherein the outer seal leg is arcuate.

[0040] Embodiment 10. The seal or assembly of any one of embodiments 7-8, wherein the outer seal leg is linear or planar.

[0041] Embodiment 11. The seal or assembly of any one of embodiments 7-9, wherein the outer seal leg comprises a first seal lip, a second seal lip, and a valley disposed between the first seal lip and the second seal lip, wherein the valley comprises a plating thickness that is greater than a plating thickness on the at least two seal lips.

[0042] Embodiment 12. The assembly of any one of embodiments 7-11, wherein the outer seal leg is in contact with the housing of the assembly.

[0043] Embodiment 13. The seal or assembly of any one of embodiments 1-12, wherein the first sealing lip and the second sealing lip of the inner sealing leg are disposed about an inner diameter of the metallic annular body of the seal.

[0044] Embodiment 14. The seal or assembly of embodiment 13, wherein the first sealing lip and the second sealing lip of the inner sealing leg form a ridge about the inner diameter of the metallic annular body of the seal.

[0045] Embodiment 15. The seal or assembly of any one of embodiments 7-14, wherein the first sealing lip and the second sealing lip of the outer sealing leg are disposed about an outer diameter of the metallic annular body of the seal.

[0046] Embodiment 16. The seal or assembly of embodiment 15, wherein the first sealing lip and the second sealing lip of the outer sealing leg form a ridge about the outer diameter of the metallic annular body of the seal.

[0047] Embodiment 17. The seal or assembly of any one of embodiments 1-16, wherein the valley of the inner sealing leg is filled with plating to form a flat sealing surface.

[0048] Embodiment 18. The seal or assembly of embodiment 17, wherein the flat sealing surface of the inner sealing leg is substantially parallel to the axis of the shaft, orthogonal to a radial width of the seal, or a combination thereof.

[0049] Embodiment 19. The seal or assembly of embodiment 18, wherein the flat sealing surface of the inner sealing leg comprises an axial length that is at least 1%, at least 2%, at least 3%, at least 4%, at least 5%, at least 10%, at least 15%, at least 20%, or at least 25% of an axial length of the metallic annular body of the seal.

[0050] Embodiment 20. The seal or assembly of embodiment 19, wherein the flat sealing surface of the inner sealing leg comprises an axial length that is no greater than 95%, no greater than 90%, no greater than 85%, no greater than 80%, no greater than 75%, or no greater than 50% of the axial length of the metallic annular body of the seal.

[0051] Embodiment 21. The seal or assembly of any one of embodiments 7-20, wherein the valley of the outer sealing leg is filled with plating to form a flat sealing surface.

[0052] Embodiment 22. The seal or assembly of embodiment 21, wherein the flat sealing surface of the outer sealing leg is substantially parallel to an axially inner surface of the housing, orthogonal to a radial width of the seal, or a combination thereof.

[0053] Embodiment 23. The seal or assembly of Embodiment 22, wherein the planar sealing surface of the outer sealing leg comprises a contact length that is at least 1%, at least 2%, at least 3%, at least 4%, at least 5%, at least 10%, at least 15%, at least 20%, or at least 25% of an axial length of the metallic annular body of the seal.

[0054] Embodiment 24. The seal or assembly of Embodiment 23, wherein the planar sealing surface of the outer sealing leg comprises a contact length that is no greater than 95%, no greater than 90%, no greater than 85%, no greater than 80%, no greater than 75%, no greater than 50%, or no greater than 25% of the axial length of the metallic annular body of the seal.

[0055] Embodiment 25. The seal or assembly of any one of Embodiments 1-24, wherein the plating thickness at the first and second sealing lips of the first and / or second sealing leg is at least 0.0005 mm, at least 0.005 mm, at least 0.01 mm, at least 0.02 mm, at least 0.025 mm, at least 0.03 mm, at least 0.04 mm, at least 0.05 mm, at least 0.10 mm, at least 0.15 mm, at least 0.20 mm, at least 0.25 mm, or at least 0.30 mm.

[0056] Embodiment 26. The seal or assembly of any one of Embodiments 1-25, wherein the plating thickness at the first and second sealing lips of the first and / or second sealing leg is no greater than 1.0 mm, no greater than 0.75 mm, no greater than 0.70 mm, no greater than 0.65 mm, no greater than 0.60 mm, no greater than 0.55 mm, no greater than 0.50 mm, no greater than 0.45 mm, no greater than 0.40 mm, no greater than 0.35 mm, no greater than 0.30 mm, or no greater than 0.25 mm.

[0057] Embodiment 27. The seal or assembly of any one of Embodiments 1-26, wherein the plating thickness at the valley of the first and / or second sealing leg is at least 0.005 mm, at least 0.01 mm, at least 0.015 mm, at least 0.02 mm, at least 0.025 mm, at least 0.03 mm, at least 0.04 mm, at least 0.05 mm, at least 0.10 mm, at least 0.15 mm, at least 0.20 mm, at least 0.25 mm, or at least 0.30 mm.

[0058] Embodiment 28. The seal or assembly of any of embodiments 1-27, wherein the plating thickness at the valley of the first sealing leg and / or the second sealing leg is no greater than 1.0 mm, no greater than 0.75 mm, no greater than 0.70 mm, no greater than 0.65 mm, no greater than 0.60 mm, no greater than 0.55 mm, no greater than 0.50 mm, no greater than 0.45 mm, no greater than 0.40 mm, no greater than 0.35 mm, no greater than 0.30 mm, or no greater than 0.25 mm, no greater than 0.05 mm, or no greater than 0.025 mm.

[0059] Embodiment 29. The seal or assembly of any of embodiments 1-28, wherein the plating thickness at the valley of the first sealing leg and / or the second sealing leg is at least 1.05 times, at least 1.10 times, at least 1.15 times, at least 1.25 times, at least 1.5 times, at least 1.75 times, at least 2.0 times, at least 2.5 times, or at least 3.0 times thicker than the plating thickness at the first and second sealing lips.

[0060] Embodiment 30. The seal or assembly of any of embodiments 1-29, wherein the plating thickness at the valley of the first sealing leg and / or the second sealing leg is no greater than 10.0 times, no greater than 9.0 times, no greater than 8.0 times, no greater than 7.0 times, no greater than 6.0 times, no greater than 5.0 times, no greater than 4.5 times, no greater than 4.0 times, or no greater than 3.5 times the plating thickness at the first and second sealing lips.

[0061] Embodiment 31. The seal or assembly of any of embodiments 7-30, further comprising: an energizing spring disposed between the inner sealing leg and the outer sealing leg.

[0062] Embodiment 32. The seal or assembly of embodiment 31, wherein the energizing spring is disposed between and in contact with an inner surface of the valley of the inner sealing leg and an inner surface of the valley of the outer sealing leg.

[0063] Embodiment 33. The seal or assembly of embodiment 32, wherein the energizing element is in contact with an inner surface of a central arcuate portion of the central body portion of the seal.

[0064] Embodiment 34. The seal or assembly of any of embodiments 31-33, wherein the energizing spring comprises a circular profile, an elliptical profile, a U-shaped profile, a V-shaped profile, or a C-shaped profile.

[0065] Embodiment 35. The seal or assembly of any of embodiments 31-34, wherein the energizing element is formed of a nickel-chromium based alloy, such as nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, copper, magnesium, tin, platinum, lead, iron, bronze, other elastic metallic material, or any combination thereof.

[0066] Embodiment 36. The seal or assembly of any one of embodiments 1-35, wherein the inner diameter of the metallic annular body of the spring is at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, at least 25 mm, at least 50 mm, at least 75 mm, at least 100 mm, at least 150 mm, at least 200 mm, at least 250 mm, at least 300 mm, or even greater.

[0067] Embodiment 37. The seal or assembly of any one of embodiments 1-36, wherein the outer diameter of the metallic annular body of the spring is at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, at least 11 mm, at least 12 mm, at least 13 mm, at least 14 mm, at least 15 mm, at least 25 mm, at least 50 mm, at least 75 mm, at least 100 mm, at least 150 mm, at least 200 mm, at least 250 mm, at least 300 mm, at least 500 mm, or even greater.

[0068] Embodiment 38. The seal or assembly of any one of embodiments 1-37, wherein the metallic annular body is formed of a nickel-chromium based alloy, such as nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, copper, magnesium, tin, platinum, lead, iron, or bronze.

[0069] Embodiment 39. The seal or assembly of embodiment 38, wherein the first sealing lip and the second sealing lip of the metallic annular body comprise a gold plating, a silver plating, an aluminum chromium nitride (AlCrN) plating, or a titanium aluminum nitride (TiAlN) plating.

[0070] Embodiment 40. The seal or assembly of embodiment 38, wherein the first sealing lip and the second sealing lip of the metallic annular body are free of plating.

[0071] Embodiment 41. The seal or assembly of any one of embodiments 38-40, wherein the plating reservation in the valley comprises a gold plating, a silver plating, an aluminum chromium nitride (AlCrN) plating, or a titanium aluminum nitride (TiAlN) plating.

[0072] Embodiment 42. The seal or assembly of any of embodiments 38-40, wherein the plating reservation in the valley comprises an injection molded or compression molded polymer.

[0073] Embodiment 43. The seal or assembly of embodiment 42, wherein the plating reservation in the valley comprises a fluoropolymer, a perfluoropolymer, PTFE, PVF, PVDF, PCTFE, PFA, FEP, ETFE, ECTFE, PCTFE, a fluorinated copolymer, a polyaryletherketone (such as PEEK, PK, PEK, PEKK, PEKEKK), a polysulfone (such as PPS, PPSU, PSU), a polyether (such as PPE or PPO), an aromatic polyamide (such as PPA) or an aliphatic polyamide (such as PA), a thermoplastic polyimide (such as PEI or TPI), a thermoplastic elastomer (such as TPE), a thermoplastic vulcanizate (such as TPV), a thermoplastic olefin (such as TPO), Teflon, or a combination thereof.

[0074] Embodiment 44. The seal or assembly of embodiment 43, wherein the plating reservation comprises one or more fillers.

[0075] Embodiment 45. The seal or assembly of embodiment 44, wherein the one or more fillers comprise carbon, graphite, graphene, mica, vermiculite, titanium dioxide (TiO2), molybdenum disulfide (MoS2), tungsten disulfide (WS2), barium sulfate (BaSO4), talc, mica, boron nitride (BN), an aromatic polyester, an inorganic filler, or a combination thereof.

[0076] Embodiment 46. The seal or assembly of embodiment 45, wherein the one or more fillers are configured to expand to fill voids left by thermally abraded or degraded polymer after the polymer abrades or degrades.

[0077] Embodiment 47. The seal or assembly of any of embodiments 1-46, wherein the inner seal leg is configured to form a radial seal with a shaft of an assembly, and wherein the outer seal leg is configured to form a radial seal with a housing of the assembly.

[0078] Embodiment 48. The assembly of any of embodiments 1-47, further comprising: a plurality of seals.

[0079] This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the invention, making and using it. Various modifications to the embodiments described in this disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other embodiments. Therefore, the claims are not intended to be limited to the expressly disclosed embodiments, but rather include all such embodiments and their equivalents that are within the scope of the following claims.

[0080] Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity can not be required, and that one or more further activities can be performed in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which activities are performed.

[0081] In the foregoing specification, concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present application as set forth in the claims below. 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 the present application.

[0082] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but can include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0083] Also, use of "one" or "an" is contemplated to be synonymous with "one or more" unless explicitly stated to the contrary.

[0084] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0085] Upon reading this specification, those skilled in the art will appreciate that, for clarity of disclosure, certain features are described in the context of separate embodiments. Conversely, those skilled in the art will appreciate that, for conciseness and clarity, features described in the context of a single embodiment can also be provided separately or in any sub-combination. Furthermore, reference to values stated in ranges includes each and every value within that range.

Claims

1. A seal comprising: a metallic annular body comprising an inner seal leg comprising a first seal lip, a second seal lip, and a valley disposed between the first seal lip and the second seal lip, wherein the valley comprises a plating reservation having a plating thickness that is greater than a plating thickness on the first seal lip and the second seal lip, wherein the valley of the inner seal leg is filled with plating to form a flat seal surface, wherein the first seal lip, the second seal lip, and the flat seal surface collectively define a contact area around an inner diameter of the metallic annular body, wherein the inner seal leg forms a radial seal with a component, and wherein the contact area is substantially parallel to the component.

2. The seal of claim 1, wherein the metallic annular body comprises a central body portion, wherein the inner seal leg extends from the central body portion, and wherein the central body portion is arcuate.

3. The seal of claim 2, wherein the metallic annular body comprises an outer seal leg, wherein the outer seal leg extends from the central body portion, and wherein the outer seal leg is arcuate, linear, or planar or a combination thereof.

4. The seal of claim 1, wherein the first seal lip and the second seal lip of the inner seal leg form a ridge around an inner diameter of the metallic annular body of the seal.

5. The seal of claim 1, wherein the flat seal surface of the inner seal leg is substantially parallel to an axis of the seal, orthogonal to a radial width of the seal, or a combination thereof.

6. The seal of claim 5, wherein the flat seal surface of the inner seal leg comprises an axial length that is at least 1% of an axial length of the metallic annular body of the seal, and wherein the flat seal surface of the inner seal leg comprises an axial length that is no more than 95% of the axial length of the metallic annular body of the seal.

7. The seal of claim 1, wherein the plating thickness at the valley of the inner seal leg is at least 1.05 times thicker than the plating thickness at the first seal lip and the second seal lip.

8. The seal of claim 1, wherein the metallic annular body is formed of a nickel-based alloy, nickel, titanium, tungsten, steel, aluminum, zinc, copper, magnesium, tin, platinum, lead, iron, or bronze.

9. The seal of claim 1, wherein the metallic annular body is formed of a nickel-chromium-based alloy, stainless steel, or spring steel.

10. The seal of claim 8, wherein the first seal lip and the second seal lip of the metallic annular body comprise a gold plating, a silver plating, an aluminum chromium nitride plating, or a titanium aluminum nitride plating.

11. The seal of claim 1, wherein the plating reservation in the valley comprises a gold plating, a silver plating, an aluminum chromium nitride plating, a titanium aluminum nitride plating, or an injection molded or compression molded polymer.

12. The seal of claim 11, wherein the injection molded or compression molded polymer comprises a fluoropolymer, polyaryletherketone, polysulfone, polyether, aromatic or aliphatic polyamide, thermoplastic polyimide, thermoplastic elastomer, or combinations thereof.

13. The seal of claim 11, wherein the injection molded or compression molded polymer comprises a perfluoropolymer.

14. The seal of claim 11, wherein the injection molded or compression molded polymer comprises a fluorinated copolymer.

15. The seal of claim 11, wherein the injection molded or compression molded polymer comprises PTFE, PVF, PVDF, PCTFE, PFA, FEP, ETFE, ECTFE, PCTFE, PEEK, PK, PEK, PEKK, PEKEKK, PPS, PPSU, PSU, PPE, PPO, PPA, PA, PEI, TPI, or combinations thereof.

16. The seal of claim 11, wherein the injection molded or compression molded polymer comprises a thermoplastic vulcanizate, a thermoplastic olefin, or combinations thereof.

17. The seal of claim 12, wherein the plating reserve comprises one or more fillers, wherein the one or more fillers comprise carbon, graphite, graphene, mica, vermiculite, titanium dioxide, molybdenum disulfide, tungsten disulfide, barium sulfate, talc, mica, boron nitride, aromatic polyesters, inorganic fillers, or combinations thereof, and wherein the one or more fillers are configured to expand to fill voids left by thermally worn or degraded polymer after the polymer is worn or degraded.

18. The seal of claim 3, wherein the inner seal leg is configured to form a radial seal with a first component of an assembly, and wherein the outer seal leg is configured to form a radial seal with a second component of the assembly.

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