Split-Body Control Valve Sealing for Cold-Temperature Leakage
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Solution Overview
Problem
Control valves used in cold-weather applications, such as hydrogen filling stations, face challenges with standard seals failing in extreme temperatures, leading to fluid leakage and reduced operational reliability.
Innovation Solution
A split-body control valve design with a lower and upper body portion, utilizing a coaxial flow path and seals operable in colder temperatures, including a valve plug and spring-energized seals to prevent fluid leakage, and a compact configuration with reduced components and potential leakage points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard seals are used in cold-weather control valves, then the valve structure remains simple, but the seals fail in extreme temperatures causing fluid leakage
Solution Approach 1:
The patent changes the material parameter of the seals by specifying seals operable in colder temperatures (e.g., PTFE seals, elastomeric seals rated for low temperatures). This material parameter change allows the seals to maintain their sealing properties in extreme cold conditions where standard seals would fail, directly resolving the contradiction between seal reliability and temperature effects.
2Ease of repair
If a split-body design is used, then access to internal components is improved, but the device complexity increases
Solution Approach 1:
The valve body is segmented into two separate portions: a first body portion and a second body portion. This segmentation allows the valve to be disassembled for maintenance and repair while maintaining a relatively simple overall structure. The split-body design enables easy access to internal components like seals and valve plugs without requiring complete disassembly, resolving the contradiction between ease of repair and device complexity.
3Reliability
If high-quality seals are used, then leakage is reduced, but the cost and manufacturing complexity increase
Solution Approach 1:
The patent specifies seals made from materials like PTFE (polytetrafluoroethylene) or low-temperature-rated elastomers that provide excellent sealing performance in cold conditions. These materials, while requiring specific manufacturing considerations, are well-established in the industry and can be manufactured using standard processes, thus achieving low leakage without excessive manufacturing complexity.
Solution Approach 2:
The spring-energized seal design allows the seal to self-adjust and maintain contact pressure against the sealing surface. The spring mechanism automatically compensates for wear and thermal contraction, reducing the need for precision manufacturing and complex adjustment mechanisms while maintaining effective sealing.
4Reliability
If spring-energized seals are used, then sealing force is improved, but the device complexity increases
Solution Approach 1:
The spring-energized seal system is designed to be self-regulating. The spring automatically adjusts the seal position and contact pressure in response to operating conditions such as temperature changes and wear. This self-adjusting mechanism provides reliable sealing force without requiring external control systems or complex adjustment mechanisms, resolving the contradiction between sealing force and device complexity.
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 split-body control valve design enhances operational reliability in cold temperatures, maintains high flow and pressure capabilities, and allows for the use of high-quality seals, reducing leakage and extending the valve's lifespan.
Implementation Method 1
spring-energized seals
Data Source
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AI summary
An example control valve includes a split valve body (101). The split valve body includes a first body portion (102), a second body portion (104), a flow path, an inlet port (106), and an outlet port (108). The flow path passes through the first body portion and the second body portion. The first body portion is coupled to the second body portion. The control valve also includes a valve seat (132). The valve seat is disposed between the first body portion and the second body portion. The control valve also includes a valve plug (136). The valve plug is movable relative to the valve seat to control fluid flow through the control valve.