Flow Control Device with Annular Rings for Seal Protection
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Solution Overview
Problem
High-pressure and high-flow rate conditions in valve systems often damage basic seals like O-rings due to erosion and mechanical stress during the unloading process, necessitating more expensive and complex exotic seals to prevent damage.
Innovation Solution
A flow control device featuring a fluid flow controller with annular members that create a leak path adjusted by pressure differentials, providing a diffuser effect to reduce fluid velocity and protect seals, which can include metal rings with split ends and inclined radial walls to enhance resilience and sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If basic seals like O-rings are used in high-pressure and high-flow rate conditions, then the valve can be simpler and less expensive, but the seals become damaged by erosion and mechanical stress during unloading
Solution Approach 1:
A flow control device is introduced as an intermediary component between the fluid stream and the seal. This device includes a body portion with an orifice, a control portion, and a fluid flow controller with annular members that create a leak path. The flow controller diffuses the high-velocity fluid flow before it reaches the seal, reducing erosion damage while allowing the use of simpler, less expensive basic seals like O-rings instead of complex exotic seals
2Reliability
If exotic seals such as bonded rubber, plastic, or ceramic seals are used to withstand high pressure during unloading, then seal durability is improved, but the valve becomes more expensive and complex
Solution Approach 1:
The flow control device serves as a mediator that protects basic seals from the harsh effects of high-pressure unloading. By diffusing the fluid flow through the annular members and leak path, the device reduces the erosive force on the seal, allowing inexpensive basic seals to perform as reliably as expensive exotic seals would have provided
Solution Approach 2:
The invention enables the use of inexpensive basic seals (O-rings, simple elastomeric seals) instead of costly exotic seals. The flow control device absorbs the wear and erosion that would otherwise damage the seal, making the cheaper seal viable for high-pressure applications
3Reliability
If the valve is opened quickly to reduce erosion damage to seals, then seal durability is improved, but control precision and safety are reduced
Solution Approach 1:
The flow control device acts as a buffer between the fluid system and the seal, allowing controlled, gradual opening of the valve. The annular members and leak path diffuse the fluid flow in a controlled manner, protecting the seal from erosion even during slow opening operations, thus eliminating the need to open the valve quickly
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces seal erosion and mechanical damage during unloading, allowing for the use of more advanced seals at lower costs and maintaining valve performance, while also enabling a more compact valve design.
Implementation Method 1
the flow controller has a leak path that is opened and closed by a pressure differential acting across the at least one annular member
Implementation Method 2
providing a diffuser effect to reduce fluid velocity and protect seals
Data Source
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AI summary
A flow control device typically for protecting a seal (20) in a valve, wherein a body portion (5) has an orifice (8) allowing fluid flow, and the valve has a control portion (10) to allow and restrict fluid flow through the orifice. The flow control device has a fluid flow controller (30) between the body portion and the control portion in the form of at least one annular ring (35), disposed in a recess in one of the body portion and the control portion (10). The fluid flow controller (30) defines a leak path through the device that is opened and closed by a pressure differential acting across the annular member. Typically the application of a pressure differential across the fluid flow controller moves the ring(s) to one end of the recess and reduces the cross sectional area of the leak path available to the fluid, thereby diffusing the fluid flow through the orifice (8).