High-Pressure Fluid Seals With Rolling Contact for Thermal Cycling
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Solution Overview
Problem
High-pressure fluid systems face premature failure due to eccentric temperatures, which cause relative motion and mismatched thermal expansion between components, leading to issues like spalling, galling, fretting, and seal extrusion, especially when containing fluids outside the range of 40° F. to 60° F.
Innovation Solution
The system employs a combination of static and dynamic seals with rolling contact interfaces, using materials with controlled thermal expansion and geometric designs to maintain continuous contact and minimize gaps, even at extreme temperatures ranging from -350° F. to 1,000° F., and pressures from 15,000 psi to 200,000 psi.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sacrificial seal material is used to seal high-pressure fluids, then the seal can accommodate thermal expansion and contraction, but the seal fails prematurely due to spalling, galling, or fretting from relative motion between components
Solution Approach 1:
The patent introduces an intermediate sealing layer formed by depositing material from the sacrificial seal onto the check valve body. This intermediate layer acts as a mediator between the high-pressure fluid and the check valve, providing a sealing surface that accommodates thermal expansion and contraction without causing spalling, galling, or fretting to the underlying components. The intermediate layer absorbs the harmful relative motion effects while maintaining the seal integrity.
Solution Approach 2:
The patent changes the physical and chemical parameters of the sealing interface by depositing a specialized coating layer with controlled material properties. This deposited layer has different friction, hardness, and thermal expansion characteristics compared to the base seal material, allowing it to maintain effective sealing under thermal cycling from -350°F to 1000°F without suffering from the harmful effects of direct component contact.
2Ease of manufacture
If components are made of the same material to simplify manufacturing, then production is easier, but relative motion causes spalling and galling due to mismatched thermal expansion rates
Solution Approach 1:
The patent applies local quality by depositing a specialized intermediate sealing layer only at the critical sealing interface between the check valve and the high-pressure fluid. This localized application of differently properties material (with controlled thermal expansion and friction characteristics) addresses the reliability issues without requiring the entire check valve assembly to be made of composite or dissimilar materials, thus maintaining ease of manufacture for the bulk components.
3Reliability
If polymeric seals are used to seal gaps between moving components, then sealing is achieved, but the seals become softer at elevated temperatures and extrude into the gap, reducing operational lifetime
Solution Approach 1:
The patent uses an intermediate deposited sealing layer as a mediator that replaces the polymeric seal. This intermediate layer maintains the sealing function while being resistant to thermal softening and extrusion. The deposited layer's material properties are specifically selected to maintain structural integrity and sealing effectiveness across the full temperature range from -350°F to 1000°F, preventing the softening and extrusion problems that plague polymeric seals.
4Ease of manufacture
If direct contact seals are used between similar materials, then manufacturing is simplified, but eccentric temperatures cause relative motion and wear on abutting components
Solution Approach 1:
The patent introduces an intermediate deposited sealing layer between the abutting components at the sealing interface. This intermediate layer acts as a mediator that prevents direct contact and relative motion between the similar materials of the check valve body and the sacrificial seal. The deposited layer absorbs the thermal expansion differences and mechanical stresses, eliminating wear on the abutting components while maintaining seal effectiveness.
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
This approach significantly extends the operational lifetime of seals from 30 hours to over 400 hours by reducing mechanical failure and maintaining effective sealing despite thermal cycling, with improved performance under eccentric temperature conditions.
Implementation Method 1
The system employs a combination of static and dynamic seals with rolling contact interfaces, using materials with controlled thermal expansion and geometric designs to maintain continuous contact and minimize gaps
Implementation Method 2
The components of known systems (e.g., vessels and pumps) expand and contract when thermally cycled (e.g., via proximity to the high or low-temperature fluid and/or via the pressurization operation) resulting in alteration of the sealing configuration
Data Source
AI summary
Disclosed herein are components, systems, and methods for sealing and pressurizing fluids at eccentric temperatures. Embodiments of a high-pressure system include static seals, dynamic seals, or both. A fluid tight seal formed between abutting surfaces of stationary, adjacent components is movable, via rolling contact between the abutting surfaces, as a temperature of the adjacent components enters the eccentric temperature range. The materials of the adjacent components may be selected based on their thermal expansion and contraction characteristics, and respective geometries of components of the high-pressure system may be selected to maintain a minimal gap between moving, adjacent components of the high-pressure system.