Ball valve, characterization orifice insert and method of making same
By introducing a characterizing orifice insert in the ball valve assembly in combination with a rotating ball, the operation of a V-port valve is mimicked, solving the problem of high production costs and achieving a flow control effect with similar performance.
Patent Information
- Application Number
- CN202380084210.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-12-06
- Filing Date
- 2023-12-06
- Publication Date
- 2025-09-23
AI Technical Summary
It is difficult with the prior art to cost-effectively produce a ball valve assembly having performance characteristics similar to a V-port valve.
The characterization orifice insert is combined with a rotating ball to simulate the operation of a V-port valve, exposing the flow path through different geometric shapes of the rotating ball to achieve flow control, combined with the use of metal materials such as stainless steel.
Achieves flow control performance similar to a V-port valve while reducing production costs.
Smart Images
Figure CN120693221A_ABST
Abstract
Description
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 430,464, filed on December 6, 2023, entitled Ball Valve, Characterized Orifice Insert, and Method of Making the Same, which is incorporated herein by reference in its entirety. Technical Field
[0003] The present subject matter relates generally to valve assemblies, and more particularly to ball valve assemblies. Background Art
[0004] A typical fluid flow valve assembly typically includes a shut off valve that includes a mechanism that is configured to allow fluid to flow therethrough in an open position and to prevent fluid flow in a closed position. Among the various types of fluid flow valve assemblies, a globe valve is one type. A typical globe valve includes a linearly movable valve disc that is configured to engage with a valve seat in a closed position to prevent fluid flow and to be positioned away from the valve seat in an open position to allow fluid to flow through the valve. Other types of fluid flow valve assemblies include standard ball valves and V-port ball valves. A standard ball valve typically includes a quarter-turn ball having a substantially cylindrical bore formed therethrough. A V-port ball valve typically includes a quarter-turn ball having a V-shaped bore extending therethrough.
[0005] V-port ball valves are a crude control valve product. Traditionally, control applications require globe valves to provide throttling and process control functions. Globe valves offer precise control and, when properly equipped, can withstand harsh environments. V-port ball valves use variable flow path geometry to achieve increased control performance. Compared to globe valves, V-port ball valves generally provide basic control performance at a lower cost, leading to a growing demand for V-port ball valves where service conditions permit.
[0006] While V-port ball valves are generally cheaper to produce than globe valves, they are generally more expensive to produce than standard ball valves. Therefore, it would be desirable to produce a ball valve assembly that has performance characteristics similar to a typical V-port valve, but that can be produced in a more cost-effective manner. BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present disclosure is illustrated by way of example and not limitation in the accompanying figures and in which like references indicate similar elements and in which:
[0008] Figure 1 is an isometric view of a ball valve assembly according to an example embodiment of the present disclosure;
[0009] Figure 2 is a schematic side cross-sectional view of a ball valve assembly according to an example embodiment of the present disclosure;
[0010] Figure 3 is a partial isometric cross-sectional schematic diagram of a ball valve assembly according to an example embodiment of the present disclosure;
[0011] Figure 4 is an exploded isometric view of an orifice insert and an end cap of a ball valve assembly according to an example embodiment of the present disclosure;
[0012] Figure 5A is a front view illustrating an orifice insert of a valve assembly according to an example embodiment of the present disclosure;
[0013] Figure 5B is a side view illustrating an orifice insert of a valve assembly according to an example embodiment of the present disclosure;
[0014] Figure 5C is an isometric view representing an orifice insert of a valve assembly according to an example embodiment of the present disclosure;
[0015] Figure 6A is a front view illustrating an orifice insert in an initial state according to an example embodiment of the present disclosure; and
[0016] Figure 6B is a front view illustrating an orifice insert in a final state according to an example embodiment of the present disclosure. DETAILED DESCRIPTION
[0017] The present disclosure will now be described more fully below with reference to example embodiments of the present disclosure. These example embodiments are described so that the present disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. Indeed, the present disclosure can be implemented in many forms and should not be construed as being limited to the embodiments set forth herein; on the contrary, these embodiments are provided so that the present disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly indicates otherwise.
[0018] As described below, embodiments of the present disclosure are directed to valve assemblies and various components and methods of making the same. Figure 1 — Figure 3 An example embodiment of a ball valve assembly 100 according to the present disclosure is shown. Specifically, Figure 1An isometric view of a ball valve assembly 100 is shown; Figure 2 A schematic side cross-sectional view of a ball valve assembly 100 is shown; Figure 3 A partial isometric cross-sectional schematic view of the ball valve assembly 100 is shown.
[0019] As shown in the figures, the ball valve assembly 100 of the depicted embodiment generally includes a handle 102 that is mechanically connected to a rotating ball 104 (schematically shown as a shaded feature in the figure). In the depicted embodiment, the rotating ball 104 includes a substantially cylindrical hole 106 extending therethrough, although in other embodiments the rotating ball may include a hole having a different shape. In the depicted embodiment, the handle 102 and the rotating ball 104 are configured such that approximately a quarter turn of the handle 102 causes the rotating ball 104 to rotate approximately a quarter turn between an open position and a closed position. In the open position, the hole 106 is aligned with the fluid flow path of the valve assembly 100 and is configured such that fluid flows through the rotating ball 104. In the closed position, the hole 106 is not aligned with the fluid flow path of the valve assembly 100, such that fluid cannot flow through the rotating ball 104. It should be noted that other embodiments do not necessarily include a handle, such as embodiments in which the rotating ball can be rotated via an automatic mechanism.
[0020] The ball valve assembly 100 of the depicted embodiment also includes two end caps, an upstream end cap 108 and a downstream end cap 110. As will be described in more detail below, the ball valve assembly 100 of the depicted embodiment also includes a signature orifice insert 112 that is configured to be positioned adjacent to the rotating ball 104. It should be noted that while the depicted embodiment includes a single signature orifice insert 112 positioned adjacent to the upstream side of the rotating ball 104, other embodiments may have different configurations. For example, in some embodiments, a single signature orifice insert may be positioned adjacent to the downstream side of the rotating ball. Still other embodiments may include a pair of signature orifice inserts, with one insert positioned adjacent to the upstream side of the rotating ball and the other positioned adjacent to the downstream side of the rotating ball.
[0021] like Figure 1 — Figure 3 As further shown, the valve assembly 100 of the depicted embodiment also includes a pair of corresponding valve body seals (upstream valve body seal 114 and downstream valve body seal 116) and a pair of corresponding valve seats (upstream valve seat 118 and downstream valve seat 120). When assembled, the valve body seals 114, 116 and the valve seats 118, 120 are configured to be compressed between the end caps 108, 110 so that the valve seats 118, 20 seal against opposite sides of the rotating ball 104 to provide a seal in the flow direction.
[0022] Also refer to Figure 4, the upstream end cap 108 of the depicted embodiment includes a counterbore or concave feature 122 that is configured to receive the characterizing orifice insert 112 therein. As shown in the figures, in a final state, the characterizing orifice insert 112 of the depicted embodiment includes an outer flange 124, a body portion 126, a positional feature 128, and a characterizing shape 130. In the depicted embodiment, the outer flange 124 of the characterizing orifice insert 112 is configured to be received within the counterbore feature 122 of the upstream end cap 108, and the positional feature 128 of the characterizing orifice insert 112 is configured to be positioned adjacent to a corresponding positional feature 132 of the upstream end cap 108. In the depicted embodiment, the respective positional features 128, 132 are configured such that, when assembled, the characterizing orifice insert 112 does not rotate (and / or minimizes rotation) relative to the upstream end cap 108.
[0023] In the depicted embodiment, the positional feature 128 characterizing the orifice insert 112 includes a female feature (e.g., a substantially half-moon-shaped cutout or recess), and the corresponding positional feature 132 of the upstream end cap 108 includes a male feature (e.g., a substantially half-moon-shaped protrusion) configured to complement the positional feature 128 of the insert 112. It should be noted that in other embodiments, positional features having other configurations are possible. For example, in some exemplary embodiments, the orifice insert may include one or more flat portions, and the end cap may include one or more complementary flat portions. In other embodiments, the orifice insert may include two or more cutouts or recesses, and the end cap may include two or more complementary protrusions. In still other embodiments, the orifice insert may include one or more protrusions, and the end cap may include one or more complementary cutouts or cutouts. In still other embodiments, the orifice insert may include any combination of recesses or protrusions, and the end cap may include a complementary combination of recesses or protrusions.
[0024] In the depicted embodiment, the body portion 126 of the orifice insert 112 has a hemispherical shape that is configured to substantially match (or closely match) the outer diameter of the rotating ball 104. In the depicted embodiment, this allows for a tightly controlled clearance between the rotating ball 104 and the orifice insert 112. While various configurations are possible, it is believed that an insert having a hemispherical body portion is more desirable than a flat insert, which may require a larger clearance between the rotating ball and the insert. It is further believed that such a configuration may not be conducive to the desired throttling behavior of a V-port valve.
[0025] In the depicted embodiment, the rotating ball 104, the end cap 108, and the characterizing orifice insert 112 are made of a metal material, such as stainless steel. However, in other embodiments, any one or any combination of them may be made of other materials, including, for example, other metals such as carbon steel, duplex stainless steel, super duplex stainless steel, nickel, Hastelloy C, or Alloy 20. Non-metallic materials may also be used, including, for example, ABS plastic materials.
[0026] In various embodiments, when the valve assembly of the present disclosure is subjected to fluid flow therethrough, the characterizing orifice insert and rotating ball combine to mimic (and / or approximate) the operation of a V-port valve. Specifically, when rotated, varying amounts of the "V" geometry are exposed in the flow path. As more of the "V" port is exposed, the flow area under specific conditions increases, allowing more flow through the valve. This behavior facilitates coarse process control.
[0027] refer to Figure 5A — Figure 5C , which show various views of a characterizing orifice insert according to an example embodiment of the present disclosure, the characterizing orifice insert 112 of the depicted embodiment includes a characterizing shape 130 that is formed through the body portion 126 and through which fluid flows when assembled in the valve assembly. In the depicted embodiment, the characterizing shape 130 includes a substantially V-shaped geometry. In various embodiments, the dimensions of the V-shape (e.g., the angle of the "V" and / or its length, width, and / or placement) can vary depending on the desired flow coefficient. It should be noted that in other embodiments, different shapes are possible. For example, some embodiments may include a slotted shape. Still other embodiments may include a combination of V-shapes and slotted shapes. In the depicted embodiment, the characterizing shape 130 has a substantially straight leg with a curved end and is positioned substantially centrally on the insert 112. However, as described, in other embodiments, the characterizing shape may be different and may be offset relative to the insert.
[0028] In various embodiments, the characterizing orifice inserts of the present disclosure may first be in an initial state and then may be converted and / or formed into a final state, wherein in some embodiments, the characterizing orifice insert in the final state may differ from the characterizing orifice insert in the initial state in one or more aspects. For example, the characterizing orifice inserts of some embodiments may first include a substantially flat portion having an initial characterizing shape. The characterizing orifice insert may then be formed into a final state, a portion of which may be hemispherical and which may also include a characterizing shape that differs from the initial characterizing shape.
[0029] Figure 6A Shown in the initial state 112 i An example of a characterization orifice insert is shown below. Figure 6B The final state 112 is shown f An example of a characterization of an orifice insert is shown below. Figure 6A In the depicted embodiment, in the initial state 112 i The characterization of the orifice insert below comprises a substantially flat "coin-shaped" component including an initial position feature 128 i and initial representation shape 130 i In various embodiments, the characterizing orifice insert in the initial state can be produced in a variety of different ways, including, for example, via stamping, CNC machining, sintering, water jet cutting, wire electrical discharge cutting (EDM), etc. In the depicted embodiment, in the initial state 112 i The characterization of the orifice insert below comprises a stainless steel component with an initial position feature 128 produced via CNC machining. i and initial representation shape 130 i .
[0030] Figure 6B The final state 112 is shown f Next Figure 6A In the depicted embodiment, in the initial state 112 i The characterization of the orifice insert is formed via a stamping and / or die-stamping process into a final state 112 f To produce this final state, the characterizing orifice insert in the initial state 112i is formed to produce a hemispherical body portion 126 and an outer flange 124 extending around the component.
[0031] In the depicted embodiment, the initial position feature 128 i and final position feature 128 f substantially the same; however, the initial characterization shape 130 iand the final representation shape 130 f In particular, in the depicted embodiment, the initial state 130 i The characterization shape below is specifically constructed and designed so that after being transformed and / or formed, the final characterization shape 130 f In this manner, in various embodiments, one or more portions of a contour defining a characterizing shape may be initially constructed and designed to produce the desired shape after conversion and / or forming into a final component. For example, in the depicted embodiment, the desired final characterizing shape 130 f including a substantially straight leg 134 f , 136 f The basic V-shaped opening, such as Figure 6B However, in order to achieve this shape, the initial state 134 i , 136 i The legs of the characterizing shape below are curved, as Figure 6A As shown, to account for the subsequent curvature of the main body portion 126. In some embodiments, a mathematical formula can help define an initial characterizing shape that will result in a desired final characterizing shape after transformation and / or forming. For example, in some embodiments, such a mathematical formula can include as input variables one or more properties of the characterizing orifice insert, including, for example, the final dimensions of the characterizing shape, a specific material, a desired final surface diameter, and / or thickness of the insert.
[0032] Many modifications and other embodiments of the present disclosure will occur to those skilled in the art having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the disclosure is not limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims
1. A method for manufacturing a ball valve assembly, the method comprising: A pair of end caps are provided; providing a spinning ball including a hole formed therethrough; providing a handle operatively connected to the rotating ball and configured to rotate the rotating ball; providing a characterizing orifice insert, the characterizing orifice insert comprising a characterizing shape; positioning the rotating ball between a pair of the end caps; as well as positioning the characterization orifice insert adjacent to the rotating sphere, Wherein, before positioning the characterizing orifice insert near the rotating ball, the characterizing orifice insert is transformed and / or formed from an initial state to a final state, wherein the characterizing shape of the characterizing orifice insert in the initial state is different from the characterizing shape of the characterizing orifice insert in the final state.
2. The method according to claim 1, characterized in that The characteristic shape characterizing the orifice insert in the final state comprises a V-shaped opening having substantially straight legs, and wherein the characteristic shape characterizing the orifice insert in the initial state comprises a V-shaped opening having curved legs.
3. The method according to claim 1, characterized in that The characterizing aperture insert is converted and / or formed into the final state via a stamping and / or molding process.
4. The method according to claim 1, wherein The step of positioning the characterizing orifice insert includes positioning the characterizing orifice insert adjacent an upstream side of the rotating sphere.
5. The method according to claim 1, wherein The step of positioning the characterizing orifice insert includes positioning the characterizing orifice insert adjacent a downstream side of the rotating sphere.
6. The method according to claim 1, wherein The step of providing the characterization orifice insert includes providing a first characterization orifice insert and providing a second characterization orifice insert, and wherein the step of positioning the characterization orifice insert includes positioning one of the first characterization orifice insert or the second characterization orifice insert near the upstream side of the rotating sphere and positioning the other of the second characterization orifice insert or the first characterization orifice insert near the downstream side of the rotating sphere.
7. The method according to claim 1, characterized in that Also included is providing a pair of corresponding upstream and downstream valve body seals and a pair of corresponding upstream and downstream valve seats, and positioning the upstream and downstream valve body seals and the upstream and downstream valve seats so that they are compressed between the end caps.
8. The method according to claim 1, characterized in that The characterizing orifice insert includes an outer flange and a body portion, and wherein the characterizing shape is defined in the body portion.
9. The method according to claim 1, characterized in that At least one of the end caps includes a counterbore defined therein, and wherein the counterbore is configured to receive at least a portion of the characterizing orifice insert.
10. The method according to claim 1, characterized in that The characterizing orifice insert includes a position feature, and wherein at least one of the end caps includes a corresponding position feature configured to engage with the position feature of the characterizing orifice insert.
11. A ball valve assembly comprising: a pair of end caps; a rotating ball disposed between the end caps, the rotating ball including a hole formed therethrough; a handle operatively connected to the rotating ball; as well as a characterizing orifice insert positioned adjacent the rotating sphere, the characterizing orifice insert comprising a characterizing shape, wherein the handle is configured to rotate the rotating ball relative to a pair of the end caps between at least a first position and a second position, wherein in the first position the hole is substantially aligned with the characterizing shape, and in the second position the hole is substantially perpendicular to the characterizing orifice insert, and wherein the characterizing orifice insert first exists in an initial state before being converted and / or formed into a final state, wherein the characterizing shape of the characterizing orifice insert in the initial state is different from the characterizing shape of the characterizing orifice insert in the final state.
12. The ball valve assembly according to claim 11, wherein: The characteristic shape characterizing the orifice insert in the final state comprises a V-shaped opening having substantially straight legs, and wherein the characteristic shape characterizing the orifice insert in the initial state comprises a V-shaped opening having curved legs.
13. The ball valve assembly according to claim 11, wherein: The characterizing aperture insert is converted and / or formed into the final state via a stamping and / or molding process.
14. The ball valve assembly according to claim 11, wherein: The characterizing orifice insert is located adjacent the upstream side of the rotating sphere.
15. The ball valve assembly according to claim 11, wherein: The characterizing orifice insert is located adjacent the downstream side of the rotating sphere.
16. The ball valve assembly according to claim 11, wherein: The characterization orifice insert includes a first characterization orifice insert and also includes a second characterization orifice insert, and wherein one of the first characterization orifice insert or the second characterization orifice insert is located near the upstream side of the rotating ball, and the other of the first characterization orifice insert or the second characterization orifice insert is positioned near the downstream side of the rotating ball.
17. The ball valve assembly according to claim 11, wherein: Also included are a pair of corresponding upstream and downstream valve body seals and a pair of corresponding upstream and downstream valve seats, and wherein each valve body seal and each valve seat is configured to be compressed between the end caps.
18. The ball valve assembly according to claim 11, wherein: The characterizing orifice insert includes an outer flange and a body portion, and wherein the characterizing shape is defined in the body portion.
19. The ball valve assembly according to claim 11, wherein: At least one of the end caps includes a counterbore defined therein, and wherein the counterbore is configured to receive at least a portion of the characterizing orifice insert.
20. The ball valve assembly according to claim 11, wherein The characterizing orifice insert includes a position feature, and wherein at least one of the end caps includes a corresponding position feature configured to engage with the position feature of the characterizing orifice insert.