Bidirectional integral metal valve seat for ball valve

Abstract

The invention relates to a metal valve seat for a ball valve, comprising: a valve seat section of the metal valve seat; a curved valve seat surface defined on the valve seat section wherein the curved valve seat surface is complementary to an outer surface of a ball plug of the ball valve; a primary spring integrally formed with the valve seat section and the curved valve seat surface; and a base integrally formed with the primary spring, the valve seat section, and the curved valve seat surface.

Description

Technical Field

[0001] The present disclosure relates to metal-seated ball valves. Metal-seated ball valves are widely used in various industries, including oil and gas, petroleum, petrochemical, chemical, power generation, pulp and paper, and mining. Metal-seated ball valves are typically used in applications requiring sealing in conditions with high operating temperatures and / or corrosive or abrasive media. Background Art

[0002] Common examples of metal seats for ball valves include the F15 / F30 MS and the R100 and R200 M1 severe service ball valves, both commercially available from Bray International, Inc. The F15 / F30 MS utilizes a one-way modular design, with a spring and seat on the upstream side of the valve and a gasket and seat on the downstream side. The back of the downstream seat is serrated to engage a graphite gasket behind the seat, preventing leakage behind the seat. The compressive load between the ball plug and the upstream seat is driven by a spring located behind the seat, which can be a wave spring. The R100 and R200 M1 severe service ball valves utilize a spring and seat on the upstream side and a seat and locking plate on the downstream side. The downstream seat of the R100 and R200 M1 severe service ball valves features a raised edge with a specified contact area behind the seat for predictable sealing behind the seat. The back side of the downstream seat is mated and lapped to mate with the raised edge, providing a designed contact area to optimize contact stresses and seal behind the seat. Similar to the F15 / F30 MS, the compressive load between the ball plug and the upstream seat in the R100 and R200 M1 severe service ball valves is driven by a spring behind the seat, although this spring can be a wave spring or Belleville spring. Conventional embodiments, such as the F15 / F30 MS and R100 and R200M1 severe service ball valves, demonstrate the limitations of these valves, as they are designed to seal in only one direction. Other conventional models may feature springs behind both seats and an additional elastomer to assist with the peripheral sealing of the downstream seat, allowing for bidirectional use. While this allows for bidirectional operation, it limits the temperature range, making it unsuitable for high-temperature applications, such as those exceeding 450°F.

[0003] Conventional standard floating ball valve seats also typically have at least two common leak paths: between the seat and the ball plug, and behind the seat. In soft-seat floating ball valves, these leak paths can be addressed by designing in compressive stress or O-rings. In metal-seated floating ball valves, the compressive stress between the seat and the ball plug is generated by a spring and a specified contact area; leakage behind the seat is usually prevented by a graphite gasket or a mating lapped backing (also by having a specified contact area for predictable stress). To simplify design and improve predictability, metal-seated floating ball valves can be designed as unidirectional, with a spring applying stress behind a specified upstream seat, and a downstream seat with a gasket and / or mating lapped backing behind the downstream seat.

[0004] Therefore, there is a need for an improved metal seat for a ball valve that allows bidirectional use; eliminates or minimizes leak paths common in conventional models; prevents debris and particles from interfering with the metal seat and spring; allows for customized spring design; enables tighter control of contact stresses; and enables better control of torque in the ball valve. Summary of the Invention

[0005] The present disclosure relates to a metal valve seat for a ball valve, comprising: a valve seat segment of the metal valve seat; a curved valve seat surface defined on the valve seat segment, wherein the curved valve seat surface can be complementary to the outer surface of a ball plug of the ball valve; a main spring integrally formed with the valve seat segment and the curved valve seat surface; and a base integrally formed with the main spring, the valve seat segment and the curved valve seat surface.

[0006] The present disclosure may also relate to a metal valve seat for a ball valve, comprising: a valve seat segment of a metal valve seat; and / or a curved valve seat surface defined on the valve seat segment, wherein the curved valve seat surface may complement the outer surface of a ball plug of the ball valve; and / or a main spring integrally formed with the valve seat segment and / or the curved valve seat surface; and / or a base integrally formed with the main spring, the valve seat segment and / or the curved valve seat surface; and / or a coating covering the curved valve seat surface, wherein the hardness of the coating may be greater than the hardness of the valve seat segment; and / or wherein the main spring defines a gap, and / or further comprises a secondary spring inserted into the gap; and / or wherein, The main spring may form a first pointed ridge shape in a cross-sectional view of the main spring; and / or wherein the first pointed ridge may define a first vertex on an outer surface of the main spring; and / or wherein the main spring may form a second pointed ridge shape in a cross-sectional view of the main spring, and / or wherein the second pointed ridge may be connected to the first pointed ridge and / or define a second vertex on an inner surface of the main spring; and / or wherein the main spring may be composed of a first material and / or the valve seat segment may be composed of a second material, and / or further, wherein the first material and the second material may be different; and / or wherein the valve seat segment, the main spring and / or the base may be produced by an additive manufacturing method.

[0007] The present disclosure may also relate to a valve having a valve body, comprising: a ball plug located in the valve body, wherein the ball plug defines an outer surface; and / or a first metal valve seat inserted into the valve body upstream of the ball plug; and / or a second metal valve seat inserted into the valve body downstream of the ball plug; and / or wherein each of the first metal valve seat and / or the second metal valve seat may comprise: a curved valve seat surface complementary to the outer surface of the ball plug defined on the first metal valve seat and / or the second metal valve seat, respectively; and / or a main spring integrally formed with each curved valve seat surface; and / or a base integrally formed with each main spring and / or each curved valve seat surface; and / or wherein the first metal valve seat and / or Each of the second metal valve seats includes a gasket seal inserted between the back side of the base and / or the valve body; and / or wherein each main spring in the first metal valve seat and / or the second metal valve seat can define an upper gap defined by the valve body, and / or also include a secondary spring inserted into the upper gap; and / or wherein each main spring in the first metal valve seat and / or the second metal valve seat can define a lower gap leading to the valve body hole, and / or also include a secondary spring inserted into the lower gap; and / or wherein each main spring can have a bellows shape; and / or wherein the curved valve seat surface, main spring and / or base of each of the first metal valve seat and / or the second metal valve seat can be produced by an additive manufacturing method.

[0008] The present disclosure may also relate to a method of using a ball valve, comprising the following steps: disposing a ball plug within the ball valve, wherein the ball plug defines an outer surface; and / or disposing a first metal valve seat upstream of the ball plug; and / or disposing a second metal valve seat downstream of the ball plug; and / or wherein each of the first metal valve seat and / or the second metal valve seat may include: a curved valve seat surface defined on each of the first metal valve seat and / or the second metal valve seat that is complementary to the outer surface of the ball plug; a main spring integrally formed with each curved valve seat surface; and / or a base integrally formed with each main spring and / or each curved valve seat surface; and / or a base formed by the curved valve seat surface, the main spring and / or each of the first metal valve seat and the second metal valve seat. and / or further comprising the steps of: applying torque consistently; reducing torque; and / or providing a valve seat according to ANSI / FCI 70-2; and / or further comprising the steps of maintaining a seal between the ball plug and / or each curved seating surface defined on the first metal valve seat and / or the second metal valve seat independently of line pressure; and / or wherein the main spring of the first metal valve seat and / or the second metal valve seat provides a consistent spring load on both sides of the ball plug; and / or further comprising the steps of wearing the ball valve in a consistent wear pattern.

[0009] The present disclosure also relates to a method for manufacturing a ball valve, which includes the following steps: depositing one or more layers of material to produce an integral valve seat having a valve seat base, a main spring section and / or a valve seat section; and / or pair-grinding the surface of the integral valve seat; and / or further including the following steps: covering the surface of the integral valve seat with a coating having a hardness greater than that of the integral valve seat material; and / or wherein the surface of the integral valve seat can be limited to the inner surface of the valve seat section and / or can be formed into an arc to complement the ball plug of the ball valve; and / or further including the following steps: assembling the ball plug and / or the integral valve seat under non-pressure conditions; and / or wherein the step of depositing one or more layers of material includes the following steps: depositing a first group of first material layers and / or depositing a second group of second material layers, and / or wherein the first material has a different metal composition from the second material; and / or wherein the main spring section can be composed of the second material; and / or wherein the first material and / or the second material can be composed of a metal mixture. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Those skilled in the art may better understand the exemplary embodiments and make their numerous objects, features, and advantages apparent by referring to the accompanying drawings. These drawings are intended only to illustrate exemplary embodiments and should not be considered limiting of the scope of the present disclosure, as the present disclosure may encompass other equally effective exemplary embodiments. The drawings are not necessarily drawn to scale, and certain features and views in the drawings may be shown exaggerated in scale or in schematic form for the sake of clarity and conciseness.

[0011] Figure 1 A cross-sectional view of an exemplary embodiment of a ball valve having a bi-directional integral metal valve seat and ball plug is shown.

[0012] Figure 2 Shown Figure 1 An enlarged partial cross-sectional view of an exemplary embodiment of a metal valve seat and ball plug.

[0013] Figure 3A An isometric view of an exemplary embodiment of a bi-directional, one-piece metal valve seat for a ball valve is shown.

[0014] Figure 3B A front view of an exemplary embodiment of a bi-directional, one-piece metal valve seat for a ball valve is shown.

[0015] Figure 4 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve is shown.

[0016] Figure 5 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve with a double-angle shaped spring is shown.

[0017] Figure 6 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve having a spring with an outer convex circular shape is shown.

[0018] Figure 7 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve having a reentrantly shaped spring is shown.

[0019] Figure 8 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve having a spring with a concave round shape is shown.

[0020] Figure 9 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve with a serpentine-shaped spring is shown.

[0021] Figure 10A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve with a disc-shaped spring or Belleville spring is shown.

[0022] Figure 11 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat for a ball valve with a main spring, an integral wave spring, and a ball plug is shown.

[0023] Figure 12 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve with a main spring, an external Belleville spring is shown.

[0024] Figure 13 A partial cross-sectional view of an alternative exemplary embodiment of a metal valve seat and ball plug for a ball valve with a primary spring and a secondary external wave spring is shown. DETAILED DESCRIPTION

[0025] The following description includes exemplary apparatus, methods, techniques, and instruction sequences that embody the subject technology of the present invention. However, it should be understood that the described embodiments can be practiced without these specific details.

[0026] Figure 1 A cross-sectional view of an exemplary embodiment of a ball valve 60 is shown having a bi-directional integral metal valve seat 10 and a ball plug 50 in upstream and downstream positions. Figure 2 Shown Figure 1 FIG2 is an enlarged partial cross-sectional view of an exemplary embodiment of a metal valve seat 10 and a ball plug 50. The ball valve 60 includes a valve body 61 defining a valve body bore 62 extending longitudinally through the valve body 61, through which a valve medium can flow. The flow of the valve medium can be controlled by rotating the opening 52 of the ball plug 50 and thereby aligning or deflecting the opening 52 of the ball plug 50 within the bore 62 of the valve body 61. The ball plug 50 has a substantially spherical outer surface 51 and is rotatable within one or more metal valve seats 10 via a valve stem 63.

[0027] The metal valve seat 10 is integral, one-piece, or formed as a single unit / unit, having the valve seat segment 12, the spring 30 (or main spring or main spring segment 30), and the base 20, and is inserted into the valve body 61. When viewed as a whole in an isometric view, the metal valve seat 10 may have a substantially toroidal, annular, or doughnut-shaped appearance or shape (see, e.g., Figure 3A). The valve seat segment 12 of the metal valve seat 10 defines a curved surface, valve seat surface, arcuate surface, valve seat surface or valve seat interface 11, which can be matched with the outer surface 51 of the ball plug 50 by a matching grinding or arcuate design. The matching grinding process of the valve seat surface 11 ensures the sealing effect between the valve seat surface 11 and the outer surface 51 and prevents leakage paths caused by surface defects that may exist on the valve seat surface 11. The metal valve seat 10 can be used in upstream and downstream positions of the ball plug 50, such as Figure 1 As shown, the metal valve seat 10 is located on both sides of the ball plug 50 near the inner hole 62. Alternatively, as needed, the metal valve seat 10 can also be used only in one of the upstream or downstream positions of the ball plug 50. In contrast, conventional metal-seated ball valves generally must use a first valve seat arrangement for the upstream side of the ball plug 50 and a different valve seat arrangement for the downstream side to achieve effective sealing and prevent leakage.

[0028] Figure 3A An isometric view of the bi-directional integral metal valve seat 10 is shown, which further illustrates the integral nature of the valve seat segment 12, spring 30 and base 20 of the metal valve seat 10, as well as the annular structure of each component (valve seat segment 12, spring 30 and base 20) that combines to form the metal valve seat 10. Figure 3B This is a front view of the metal valve seat 10, showing its inner and outer surfaces 13 and 14. The main spring 30 of the metal valve seat 10 connects the valve seat segment 12 and the curved valve seat surface 11 to the base 20. The main spring 30 can also function as a bellows for the metal valve seat 10, with the bellows 36 used to eliminate valve leakage and prevent debris from entering or accumulating behind the valve seat 10 and / or in the valve body 61. The spring 30 can also be preloaded or prebiased during assembly to ensure that the valve seat surface 11 maintains contact with the ball plug outer surface 51 and achieves the desired seal in both flow directions. The metal bellows barrel can optionally be integrally connected and positioned adjacent to the valve seat segment 12. The bellows 36 is a long, accordion-shaped tube. As the valve spring 30, valve seat 10, or valve seat segment 12 move, the bellows 36 expands or compresses with the movement. Thus, the bellows 36 acts as a seal, preventing the passage of process fluid. Using a spring alone is more likely to result in leakage. Therefore, in these alternative exemplary embodiments, the spring 30 and the bellows 36 work together, with the bellows 36 enhancing the leak resistance of the integral valve seat 10. The main spring 30 is integrally formed with the base 20 and the valve seat section 12 having the valve seat surface 11, eliminating a leakage path behind the valve seat 10. When the main spring 30 is installed in the valve, the main spring 30 also pushes the valve seat surface 11 toward the ball plug 50, thereby preventing or minimizing an upstream leakage path. Conventional valve seats with springs are typically made of separate components (i.e., non-integral), which allows leakage to occur between the interfaces of the components and between the components and the valve body, as well as through gaps in the conventional coil spring itself.

[0029] The main spring 30 defines a bottom or lower clearance area or void 31 in the inner surface 13 of the metal valve seat 10 between the spring 30, the base 20, and the valve seat segment 12, and opens into the bore 62 when installed in the ball valve 60. The main spring 30 also defines an upper clearance area or void 32 in the outer surface 14 of the metal valve seat 10, which is bounded by the valve body 61, the valve seat segment 12, and the spring 30, and opens into the valve body 61 when installed in the ball valve 60. An optional secondary spring 40 may be inserted into the bottom void 31 and / or the upper void 32, which may be used to enhance or improve the sealing ability of the valve seat surface 11 against the ball plug 50 (see, e.g., FIG. 1 ). Figure 4 and Figure 11-13 ). The auxiliary spring 40 can optionally be a wave spring 42, 44 (such as Figure 4 、 11 and 13) or Belleville spring 43 or disc spring (as Figure 12 As shown), although the auxiliary spring 40 can also be other types of springs known to those skilled in the art. Figure 11 In the alternative embodiment shown, the wave spring 42 can be manufactured as part of the integral valve seat 10 itself, so that the wave spring 42 is integrally connected, integrated or one-piece with the valve seat 10. Figure 12 and Figure 13 In the illustrated alternative embodiment, the disc spring 43 or wave spring 44, respectively, can be a separate or external component spring added during assembly to the integral valve seat 10. In certain embodiments, the secondary spring 40 can be omitted, and the primary spring 30 can provide sufficient sealing of the valve seat surface 11 relative to the ball plug 50.

[0030] like Figures 1 to 4 As shown, the main spring 30 has a partial cross-sectional shape 71 that is angled, ridged, grooved, or "V" shaped, wherein the apex 71a is formed within or at the outer surface 14 of the metal valve seat 10 and points toward the body 61 of the valve 60 (rather than forming, facing, or pointing toward the hole 62 of the valve body 61 or the inner surface 13 of the metal valve seat 10). Figure 1 As shown, the entire cross-sectional view of the main spring 30 on a metal valve seat 10 includes two convex shapes 71, each having its apex 71a defined on the metal valve seat outer surface 14. The shapes 71 may also be referred to as bellows or bellows shapes 71. However, the shape, form, or structure of the main spring 30 should not be limited to the cross-sectional view 71 of the outer convex shape. Figure 5-10An alternative exemplary embodiment of a main spring 30 of a monolithic metal valve seat 10 is shown, with the shape, form, or structure of the main spring 30 being shown in a partial cross-sectional view, although the spring 30 may also take other forms. While portions of the metal valve seat 10 and / or spring 30 may be shown in partial cross-sectional view, it should be understood that because the metal valve seat 10 is radially symmetrical, the entire cross-sectional view comprises a mirror image of the corresponding partial cross-sectional view of the metal valve seat 10, including the spring 30, the base 20, and the valve seat segment 12.

[0031] Figure 5 FIG3 shows a partial cross-sectional view of a double-angled shape 72 of the spring 30. The partial cross-section of the double-angled shape 72 of the spring 30 is square or rectangular (or two connected sharp corners) with a first vertex 72a formed on or directed toward the outer surface 14 of the metal valve seat 10 and a second vertex 72a formed on or directed toward the inner surface 13 of the metal valve seat 10. The double-angled shape 72 or form of the spring 30 may include or define a closed area within the two vertices 72a. Figure 6 An outer convex circular shape 73 or form of the spring 30 is shown. The partial cross-sectional view of the outer convex circular shape 73 shows the arc or curved spring 30 connecting the base 20 and the valve seat segment 12. In the outer convex circular shape or form 73, the convex side of the arc 73 is defined on the metal valve seat outer surface 14, while the concave side of the arc 73 is defined on the metal valve seat inner surface 13. Figure 7 A partial cross-sectional view 74 of an angled, pointed, grooved, or “V” shape is shown with the apex 74 a directed toward, formed at, or pointing toward the metal valve seat inner surface 13 or the aperture 62 of the valve body 61 . Figure 7 The partial cross-sectional view 74 of the spring in FIG. 7 may also be referred to as a reentrant shape 74 . Figure 8 A concave rounded shape or form 75 of the spring 30 is shown. The partial cross-sectional view of the concave rounded shape 75 illustrates the arc or curved spring 30 connecting the base 20 and the valve seat segment 12. In the concave rounded shape or form 75, the convex side of the arc 75 is defined in the inner surface 13 of the metal valve seat 10, while the concave side of the arc 75 is defined on the outer surface 14 of the metal valve seat 10. Figure 9 An "S" shaped, serpentine, wavy or undulating partial cross-sectional shape 76 of the spring 30 is shown, wherein the partial cross-section of the spring 30 may have one or more curves adjacent to each other. Figure 10 A partial cross-sectional shape 77 of a straight Belleville spring or disc spring 30 is shown, wherein the partial cross-sectional shape of the spring 30 may be linear, such as with a certain angle (including perpendicular) between the base 20 and the valve seat segment 12 .

[0032] This additive manufacturing process can produce the main spring 30 in any desired custom shape or configuration, as long as the main spring 30 is integrally connected to the base 20 and the valve seat segment 12 having the curved valve seat surface 11. Furthermore, the integral nature of the main spring 30 prevents particles, debris, and other foreign matter from entering and interfering with the metal valve seat 10 and spring 30.

[0033] The base 20 is connected to and adjacent the main spring 30 and, when installed, also defines a back face 21 adjacent the valve body 61. The back face 21 is wide enough to provide a gasket seal 22 between the back face 21 and the valve body 61 while not interfering with the floatability of the metal valve seat 10.

[0034] In an exemplary embodiment, the monolithic metal valve seat 10 (including the main spring 30, the base 20, and the valve seat segment 12 with the valve seat surface 11) can be manufactured by additive manufacturing (or 3D printing) and then machined to a mating, ground surface. "Additive manufacturing" refers to a process used to create three-dimensional articles. An example of an additive manufacturing technique is stereolithography (SLA), in which material is laid down layer by layer under computer control. These articles can be of virtually any shape or geometry and can be produced from a 3D model or other electronic data source. Other examples of additive manufacturing processes or techniques include 3D printing. Additive manufacturing processes allow the monolithic metal valve seat 10 to be composed of multiple materials. By way of example only, the base 20 can be composed of a first material and the main spring 30 can be composed of a second material, while still forming a single, monolithic component. Furthermore, the metal valve seat 10 can be constructed of a combination or hybrid of metals and / or materials through additive manufacturing. In certain exemplary embodiments, each portion of the monolithic metal valve seat 10 can be constructed of stainless steel. The metal valve seat 10 may also be made of one or more of the following materials: nickel-based alloys (such as INCONEL alloys), titanium, and other materials known to those of ordinary skill in the art. In an alternative exemplary embodiment, the integral metal valve seat 10 may be manufactured solely by machining. The additive manufacturing process may include depositing, printing, or extruding layers of material on top of, adjacent to, or in close proximity to previously deposited layers of material, wherein each layer of material may be a different or the same material as desired to form the shape of the integral, continuous, or single-piece metal valve seat 10. During the deposition of the layers, the secondary spring 40 may be inserted in an appropriate location or layer so as to form an integral body with the integral metal valve seat 10 when subsequent layers are deposited on the secondary spring 40. Subsequently, one or more surfaces of the metal valve seat 10 may be machined to the desired tolerance and / or precision, including mating grinding of the curved valve seat surface 11. The present disclosure encompasses other manufacturing processes known to those of ordinary skill in the art that are capable of producing the integral metal valve seat 10.

[0035] The valve seat surface or valve seat interface 11 can be hardened or coated with a material or coating having a higher hardness than the material of the metal valve seat 10 to enhance its resistance to corrosion, erosion, and wear when the valve seat surface 11 interacts with the ball plug 50. Any coating 16 on the valve seat surface 11 can be three-dimensionally printed on the valve seat surface 11.

[0036] Compared to the prior art, the integral metal valve seat 10 provides improved continuous torque, or operating torque, for opening and closing the valve assembly 60. Operating torque refers to the rotation of the valve stem 63, which in turn rotates the ball plug 50. This operating torque is driven by factors including the compressive stress of the valve seat 10, the stress of the packing, the coefficient of friction between the valve seat 10 and the ball plug 50, the coefficient of friction between the packing and the valve stem 63, and the pressure and characteristics of the medium.

[0037] The integral metal valve seat 10 minimizes stress on the valve seat 10, thereby achieving the desired seal without over-extruding the valve seat 10, which would increase operating torque. Conventional valve seat designs, on the other hand, take into account component tolerances, which typically result in increased seat stress. The improved integral metal valve seat 10 overcomes these tolerance and repeatability issues encountered in other conventional valve seat designs with multiple independent components, due to its integral nature. In addition, due to the nature of spring manufacturing, relying solely on an external spring to apply force may result in inconsistent force, which in turn results in inconsistent torque. By way of further example, the integral metal valve seat 10 can provide a Class VI shutoff or leakage rating in accordance with the ANSI / FCI 70-2 standard.

[0038] As a further improvement over conventional floating ball valve seats, the improved integral valve seat 10 can maintain a seal (between the valve seat 10 and the ball plug 50) without relying on line pressure or the pressure of the valve medium flow. This is due to the contact stress between the valve seat and the ball plug generated during the assembly process (in a non-pressurized state). In conventional floating ball valves, line pressure causes the ball plug to float into the valve seat and form a seal; in contrast, the integral metal valve seat 10 forms a seal during assembly (between the curved valve seat surface 11 and the ball plug outer surface 51) through pre-compression, without the need for line pressure or the valve medium to assist in forming a seal. This further supplements or improves the high-pressure pressure-assisted seal found in conventional metal-seated ball valves.

[0039] Furthermore, because of the consistent spring load from the main spring 30 (and optional secondary spring 40, if present) on both sides of the ball plunger 50, any valve 60 employing the improved integral valve seat 10 will experience a more consistent wear pattern, resulting in a longer service life compared to a check valve. In a conventional check valve, the upstream seat is typically the only seat that is spring-loaded, which can cause uneven wear. Furthermore, due to the reduced stress, the valve 60 also has a longer service life than other two-way valves.

[0040] Although the embodiments of the present invention are described with reference to various specific implementations and application scenarios, it should be understood that these embodiments are for illustration only and the scope of protection of the present invention is not limited thereto. Those skilled in the art will appreciate that the present invention is subject to many variations, modifications, supplements, and improvements.

[0041] For components, operations, or structures described herein as a single example, multiple examples may be provided. These and other variations, modifications, supplements, and improvements fall within the scope of the subject matter of the present invention.

Claims

1. A metal valve seat for a ball valve, comprising: The valve seat section of the metal valve seat; a curved valve seat surface defined in the valve seat segment, wherein the curved valve seat surface is complementary to an outer surface of a ball plug of the ball valve; a main spring integrally formed with the seat segment and the curved seat surface; and A base integrally formed with the main spring, seat segment, and curved seat surface.

2. The device according to claim 1, further comprising a coating covering the curved valve seat surface, wherein The hardness of the coating is greater than the hardness of the valve seat segment.

3. The device according to claim 2, wherein The main spring defines a gap and further includes a secondary spring inserted into the gap.

4. The device according to claim 3, wherein The main spring is formed with a first pointed ridge shape in a cross-sectional view of the main spring.

5. The device according to claim 4, wherein The first ridge defines a first apex on the outer surface of the main spring.

6. The device according to claim 5, wherein The main spring is formed with a second pointed ridge shape in a cross-sectional view of the main spring, and wherein the second pointed ridge is connected to the first pointed ridge and defines a second apex on an inner surface of the main spring.

7. The device according to claim 1, wherein The main spring is constructed of a first material and the valve seat segment is constructed of a second material, and further wherein the first material and the second material are different.

8. The device according to claim 1, wherein The valve seat segment, the main spring and the base are manufactured by an additive manufacturing method.

9. A valve having a valve body, comprising: a ball plug positioned within the valve body, wherein the ball plug defines an outer surface; a first metal valve seat inserted into the valve body upstream of the ball plug; A second metal valve seat inserted into the valve body downstream of the ball plug; Wherein, the first metal valve seat and the second metal valve seat both include: a curved valve seat surface defined on each of the first and second metal valve seats, respectively, that is complementary to the outer surface of the ball plug; main springs integrally formed with respective curved seating surfaces; and A seat is integrally formed with a respective main spring and a respective curved seating surface.

10. The device according to claim 9, wherein The first and second metal valve seats each include a gasket seal interposed between a back surface of the base and the valve body.

11. The device according to claim 10, wherein The main springs of the first metal valve seat and the second metal valve seat each define an upper space defined by the valve body, and further include a secondary spring inserted into the upper space.

12. The device according to claim 10, wherein The main springs of the first metal seat and the second metal seat each define a lower void leading to the hole of the valve body, and further include a secondary spring inserted into the lower void.

13. The device according to claim 9, wherein Each main spring has a bellows shape.

14. The device according to claim 9, wherein The curved seat surface, main spring and base in each of the first metal valve seat and the second metal valve seat are manufactured by an additive manufacturing method.

15. A method for using a ball valve, comprising the following steps: a ball plug disposed within the ball valve, wherein the ball plug defines an outer surface; A first metal valve seat is provided upstream of the ball plug; A second metal valve seat is provided downstream of the ball plug; Wherein, the first metal valve seat and the second metal valve seat both include: a curved valve seat surface defined on each of the first metal valve seat and the second metal valve seat, respectively, and complementary to the outer surface of the ball plug; main springs integrally formed with respective curved seating surfaces; and a base integrally formed with the respective main spring and the curved valve seating surface; By integrally connecting the curved seat surface, main spring, and base of each first and second metal valve seats, a leak path is prevented from forming behind each first and second metal valve seats.

16. The method of claim 15, further comprising the step of preventing erosion and wear by a coating on the curved valve seat surface.

17. The method according to claim 15, wherein: The step of preventing a leak path behind each of the first and second metal valve seats is also accomplished by forming a bellows integrally with the main spring and the curved valve seat surface.

18. The method according to claim 15, further comprising the steps of: Before the step of providing the first metal valve seat, the first metal valve seat is additively manufactured; and before the step of providing the second metal valve seat, the second metal valve seat is additively manufactured.

19. The method according to claim 16, further comprising the steps of: Consistently applies torque; reduces torque; and provides Class VI shutoff per ANSI / FCI 70-2.

20. The method according to claim 19, further comprising the steps of: A seal between the ball plug and the curved seating surfaces defined in each of the first and second metal valve seats is maintained independent of line pressure.

21. The method of claim 20, wherein the main springs of the first and second metal valve seats provide a consistent spring load on both sides of the ball plug; and further comprising the step of wearing the ball valve in a consistent wear pattern.

22. A method for manufacturing a ball valve, comprising the following steps: depositing one or more layers of material to produce a unitary valve seat having a valve seat base, a main spring segment, and a valve seat segment; and The surfaces of the integral valve seats are mating-lapped.

23. The method according to claim 22, further comprising the steps of: The surface of the integral valve seat is covered with a coating of a material having a harder hardness than that of the integral valve seat.

24. The method according to claim 23, wherein The surface of the integral valve seat is defined on the inner surface of the valve seat segment and is arc-shaped to complement the ball plug of the ball valve.

25. The method of claim 24, further comprising the step of assembling the ball plug and the integral valve seat under a non-pressurized condition.

26. The method of claim 24, wherein the step of depositing one or more layers of material comprises the steps of depositing a first set of layers of a first material and depositing a second set of layers of a second material, wherein the first material has a different metallic composition than the second material.

27. The method according to claim 26, wherein The main spring segment is composed of a second material.

28. The method according to claim 26, wherein The first material or the second material is composed of a metal mixture.

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