Patent Grant
10731762
The present description relates generally to seals. More specifically, the present invention relates to elastomeric seals that are temperature activated.
Conventional sealing devices (seals) are generally utilized to create sealed junctions between mating components that prevent the passage of liquid or gaseous fluids, such as air, water, refrigerants and the like, through the junction under certain operating temperatures and pressures. Seals are typically fabricated from one or more elastomers, such as thermoplastic elastomers, various rubbers or the like, that are compatible with the environmental conditions they will be subjected to at those operating temperatures and pressures.
However, conventional seals typically have a fixed modulus of elasticity (“Young's modulus” or “modulus”) which must be suitable for the operating conditions of a given application. The fixed modulus can be problematic, especially for seals having operating pressure and temperatures that are substantially higher than the pressures and temperatures the seals are subjected to during installation (i.e., installation temperatures and pressures) of the seal in the junction between the mating components. For high operating pressures, a seal will usually require a high modulus and will generally be very stiff and difficult to work with during installation. Additionally for such high pressures, the seals must be installed with an interference fit between components, which could potentially damage the seal upon installation. Moreover, if a seal is additionally subjected to high operating temperatures, the seal's elastomeric body will have a tendency to soften, which could lead to extrusion under high operating pressures that could also damage the seal or cause the seal to leak.
Accordingly, there is a need for an elastomeric sealing device for high pressure-high temperature applications, which is easy to install and does not require an interference fit at installation temperatures and pressures.
Aspects of the present invention, which provide temperature activated elastomeric sealing devices that overcome the limitations of conventional sealing devices, are disclosed. Though some aspects of the present description may be directed toward the fabrication of components for the oil and gas industry, aspects of the present invention may be employed in the fabrication of any component on any industry, in particular, those components requiring high temperature-high pressure sealing applications.
The present invention offers advantages and alternatives over the prior art by providing an elastomeric sealing device operable at an operating temperature above an installation temperature. The sealing device includes a body fabricated from an elastomeric material and a channel formed within the body. A mesh is disposed within the channel. The mesh including a plurality of interwoven fibers forming an inner volume. A filler is disposed within the inner volume, wherein at least a portion of the filler is a liquid at the installation temperature, and wherein the at least a portion of the filler is a gas at the operating temperature. In some embodiments the sealing device has an operating pressure and an installation pressure wherein the at least a portion of the filler is a liquid at the installation pressure, and the at least a portion of the filler is a gas at the operating pressure.
In some embodiments the elastomeric sealing device operates within a temperature range of 65 to 260 degrees C. In other embodiments the sealing device operate within a pressure range of 100 pounds per square inch (psi) to 30,000 psi. In other embodiments the sealing device has an installation temperature within a range of 0 degrees centigrade to 25 degrees centigrade. In other embodiments the installation pressure is substantially equal to the operating pressure.
In another aspect of the invention, the elastomeric sealing device includes an inner liner disposed between the filler and mesh.
In other embodiments, the mesh of the elastomeric sealing includes a first group of fibers arranged at a first angle with respect to a longitudinal axis of the mesh. Additionally, the mesh includes a second group of fibers arranged at a second angle with respect to the longitudinal axis of the mesh, wherein the second angle is substantially opposite and substantially equal to the first angle. In some embodiments the first angle is within a range of 50 to 60 degrees. In other aspects of the invention, the fibers of the mesh are substantially inextensible.
In some embodiments the elastomeric material of the body of the sealing device is a polymer. In some aspects of the invention, the elastomeric material is a rubber. In other embodiments, the inner liner of the sealing device is an elastomeric material.
In some embodiments the sealing device may have an annular shape. In other embodiments the invention, the sealing device may be used as an o-ring.
In yet another embodiment of the invention, the elastomeric sealing device's body includes an arcuate shaped portion having a first end and a second end, a first flange integrally connected to the first end and a second flange integrally connected to the second end. In other embodiments the elastomeric sealing device is a packer element for one of a zonal isolation device and a blow-out preventer.
In other embodiments of the invention, the elastomeric sealing device includes a first effective modulus attributable to the elastomeric sealing devices at the installation temperature and the installation pressure. The device also includes a second effective modulus attributable to the elastomeric sealing device at the operating pressure and operating temperature, wherein the second effective modulus is larger magnitude than the first effective modulus. In some embodiments, the second effective modulus is between 2 to 3 orders of magnitude greater than the first effective modulus.
In some embodiments, the filler of the elastomeric sealing device is composed of thermally expandable microspheres.
These and other aspects, features, and advantages of this invention will become apparent from the following detailed description of the various aspects of the present invention taken in conjunction with the accompanying drawings.
The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the present invention will be readily understood from the following detailed description of aspects of the invention taken in conjunction with the accompanying drawings in which:
Certain exemplary embodiments of the present invention will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the methods, systems, and devices disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the methods, systems, and devices specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention.
U.S. patent application Ser. No. 14/068,773, filed on Oct. 31, 2013, having Publication No. US2015/0115535 A1 and titled “Seal Having Variable Elastic Modulus” to inventors Trivedi et al (the Trivedi application) describes a prior art seal having a variable modulus. The seal described in Trivedi includes a body fabricated from an elastomeric material. A channel is formed within the body and a tube is disposed within the channel. The tube is comprised of a plurality of interwoven fibers. Trivedi also includes an inlet in an outer surface of the body, wherein the inlet is fluidly coupled to an inner volume of the tube.
The Trivedi seal requires a source of high pressure fluid, such as a high pressure pump, a pressurized accumulator or the like, to pump pressurized fluid through the inlet and into the inner volume of the tube in order to vary the effective modulus of the seal. Additionally, a valve must be used to contain the fluid under pressure and control the seal's modulus. The Trivedi seal must be perforated to accommodate the inlet, which could potentially damage the seal. Moreover, the need for a valve and a source of high pressure fluid can be expensive and adds to the complexity of the installation process.
Accordingly, there is a need for an elastomeric sealing device with a variable modulus that does not require external apparatus, such as high pressure pumps or valves, to activate.
Referring to
At least a portion of the filler 22 is a liquid at installation temperatures and pressures, which are generally at, or near, the standard atmospheric temperature of 25 degrees C. and the standard atmospheric pressure of one atmosphere (or 14.7 psi). However, one skilled in the art would recognize that installation temperature or pressure may vary substantially from such standard atmospheric temperature and pressure. For example, the installation temperature could be within a range of 0 degrees C. to 50 degrees C.
At such installation temperatures and pressures the interwoven fibers 18 of mesh 16 are flexible and pliable. Accordingly, sealing device 10 has an effective first modulus of elasticity that is relatively low at installation conditions.
At elevated operating temperatures, the portion of the filler 22 that is a liquid at installation temperatures and pressures changes phase from a liquid to a gas and pressurizes the interwoven fibers 18 of sealing device 10. The interwoven fibers 18 come under tension when pressurized by the vaporized portion of the filler 22, which causes the mesh 16 to expand radially and, due to the inelastic properties of the fibers 18, to contract longitudinally. This substantially increases the effective modulus of the sealing device 10 from the first modulus to a much higher second modulus of elasticity. In some cases the second modulus is up to 2 to 3 orders of magnitude greater than the first modulus. The increased stiffness of sealing device 10 compensates for any softening of the elastomeric body 12 due to elevated operating temperatures. Additionally, the radial expansion of mesh 16 causes an interference fit to be created, leading to an effective seal.
The filler can be composed of any number of low boiling liquids or gels, the gels having a substantial liquid component. In a preferred embodiment, the filler is composed of a large plurality of thermally expandable microspheres. Microspheres are commercially available and can be purchased from such companies as Chase Corporation in Westwood, Mass., USA or Kureha in Osaka, Japan.
Referring to
When heat energy 32 is applied to microsphere 26, the shell 28 softens. Additionally the encapsulated hydrocarbon 30 changes state from a liquid to a gas, which exerts an outward pressure (shown by arrows 34) on the shell 28, causing expansion. The expanded diameter of microsphere 26 can increase by 3 to 5 times and the expanded volume of microsphere 26 can increase from 50 to 100 times over its unexpanded diameter and volume. A typical range of diameters for microsphere 26 can vary from 10 to 50 microns in the unexpanded state up to 30 to 200 microns in the expanded shape.
Microspheres 26 have a wide range of variable features that can be used to match a particular application's requirements, including the chemical composition of the shell 28 and encapsulated hydrocarbon 30, wall thickness of the shell 28, overall size of the microsphere 26 and the shape of the microsphere. Accordingly, as a main component of filler 22, the microspheres 26 can be designed to operate in such divers operating temperature ranges as from 65 degrees C. to 260 degrees C. and operating pressure ranges as from 100 psi to 30,000 psi.
Moreover, the filler 22 can be composed of more than one type of microspheres 26, each type being tuned to operate in a specific operating temperature and pressure to provide a stepped change in the effective modulus, and therefore stiffness, to sealing device 10 as the operating temperature increases. For example, there can be at least a first type of microsphere 26 and a second type of microsphere 26. The first type of microspheres selected to start its expansion within a first operating temperature range (for example 90 to 95 degrees C.) and the second type of microsphere selected to start its expansion within a second operating temperature range (for example 140-145 degrees C.), wherein the second operating temperature range is higher than the first operating temperature range. In this way, the stiffness of sealing device 10 can adjust in a step wise fashion to compensate for rising operating temperatures and the rising operating pressures that are associated with those higher operating temperatures.
A commercial example of two types of microspheres 26 that could potentially be combined together as part of the filler 22 for sealing device 10 to provide a stepped change in effective modulus and stiffness as operating temperatures rise would be Chase Corporation's microsphere part numbers U018-130D and U017-175D. The U018-130D microsphere has an expansion start temperature range of 90 to 95 degrees C. and an optimum expansion temperature range of 130 to 140 degrees C. The U017-175D microsphere has an expansion start temperature range of 140 to 145 degrees C. and an optimum expansion temperature range of 175-185 degrees C.
The body 12 may comprise any shape suitable to form a seal between components in a desired application and may be dependent on the size and/or shape of the components. For example, the body 12 may be substantially annular shaped (e.g., in applications where the seal 10 may be utilized as an o-ring). Alternatively, the body 12 may have an arcuate or substantially semicircular shape (e.g., in applications where the seal 10 may be utilized as a packer element for a zonal isolation device or blow out preventer (BOP), such as a fixed bore ram, annual packer, variable ram packer (Hydril), or the like), such as described below with respect to
The body 10 may be fabricated from any elastomeric material that is compatible with process conditions of a desired application. For example, the body 12 may be fabricated from a polymer, such as a rubber compound, silicone or the like. In embodiments where the body 12 is fabricated from a rubber compound, the compound may be based on any suitable rubber compound, for example, such as nitrile butadiene rubber, natural rubber, or the like.
The channel 14 may be disposed in any position within the body 12 suitable to facilitate a phase change of at least a portion of the filler 22 and, therefore, a transition from the first modulus to the higher second modulus of the sealing device 10 throughout at least a portion of the sealing device 10. For example, in embodiments where the body 12 is substantially annular shaped, the channel 14 may also be annular in shape and disposed within the body 12 such that the channel 14 is concentric with the body 12, such as shown in
The fibers 18 of mesh 16 may be fabricated from any substantially inelastic material. For example, the fibers may be fabricated from a polymer based material, such as nylon, polyester, cotton, rayon or the like. The fibers may also be high performance carbon fibers.
The optional inner liner 24 functions to prevent leakage of the filler 22 through the mesh 16 and body 12, especially in embodiments where the mesh 16 is porous. In addition, the inner liner 24 may prevent exposure of the plurality of fibers 18 to the filler disposed within the inner volume 20, thereby preventing or reducing degradation of the plurality of fibers 18. The inner liner 24 may be fabricated from any elastomeric material that is compatible or non-reactive with the filler and may be dependent on a desired application. For example, the inner liner 24 may be fabricated from a polymer, such as a rubber compound, silicone or the like.
Referring to
Referring to
The plurality of interwoven fibers 18 may be configured in any manner suitable to facilitate the increase or decrease in the elastic modulus of the seal as described above. In the exemplary embodiment of
Referring to
The mesh 16 is configured to provide a variable modulus throughout the arcuate portion of the body 12 that would interface with a surface of a pipe, tube, bore, or the like. The mesh 16 is sized such that a first end 58 of the arcuate mesh 16 extends proximate the first end 50 of the arcuate body 12 and a second end 60 of the mesh 16 extends proximate the second end 52 of the body 12.
Referring to
Even though the exemplary operational embodiment of
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the various embodiments without departing from their scope.
While the dimensions and types of materials described herein are intended to define the parameters of the various embodiments, they are by no means limiting and are merely exemplary. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the various embodiments should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. .sctn.112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
It is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention.
Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the present invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 829546 | Schou | Aug 1906 | A |
| 1439452 | Shaw | Dec 1922 | A |
| 1966202 | Pfefferle | Jul 1934 | A |
| 3178779 | Clark | Apr 1965 | A |
| 3359687 | Wallace | Dec 1967 | A |
| 3642291 | Zeffer | Feb 1972 | A |
| 3788651 | Brown | Jan 1974 | A |
| 3934889 | Smith | Jan 1976 | A |
| 4078832 | Wittman | Mar 1978 | A |
| 4269419 | Brant | May 1981 | A |
| 4300775 | Ringel | Nov 1981 | A |
| 5580068 | Gundy | Dec 1996 | A |
| 6820666 | Nahmias Nanni et al. | Nov 2004 | B2 |
| 6896063 | Chang et al. | May 2005 | B2 |
| 7188678 | Richard et al. | Mar 2007 | B2 |
| 7617874 | Ocalan | Nov 2009 | B2 |
| 7743825 | O'Malley et al. | Jun 2010 | B2 |
| 7857066 | DiFoggio et al. | Dec 2010 | B2 |
| 8240392 | Barnard et al. | Aug 2012 | B2 |
| 8276918 | Gilstad | Oct 2012 | B1 |
| 8397836 | Pool et al. | Mar 2013 | B2 |
| 8403337 | Gilstad | Mar 2013 | B1 |
| 8439082 | O'Connell | May 2013 | B2 |
| 8443892 | Richard et al. | May 2013 | B2 |
| 8464787 | O'Malley | Jun 2013 | B2 |
| 8602419 | Namuduri et al. | Dec 2013 | B2 |
| 8616276 | Tips et al. | Dec 2013 | B2 |
| 8646537 | Tips et al. | Feb 2014 | B2 |
| 8684100 | Tingler et al. | Apr 2014 | B2 |
| 8739408 | Duan et al. | Jun 2014 | B2 |
| 8794639 | Westhoff | Aug 2014 | B2 |
| 8955606 | O'Malley | Feb 2015 | B2 |
| 8960314 | Ramon et al. | Feb 2015 | B2 |
| 10029550 | Richert | Jul 2018 | B2 |
| 20020063398 | Norman-Martin | May 2002 | A1 |
| 20050077683 | Comert | Apr 2005 | A1 |
| 20050187331 | Yuan | Aug 2005 | A1 |
| 20060272826 | Shuster et al. | Dec 2006 | A1 |
| 20070193736 | Corre | Aug 2007 | A1 |
| 20080264647 | Li | Oct 2008 | A1 |
| 20100310385 | Denne | Dec 2010 | A1 |
| 20110293958 | Benkoski | Dec 2011 | A1 |
| 20120025471 | Andrick | Feb 2012 | A1 |
| 20120055667 | Ingram et al. | Mar 2012 | A1 |
| 20120139250 | Inman et al. | Jun 2012 | A1 |
| 20120205105 | Le Roy-Delage et al. | Aug 2012 | A1 |
| 20120205106 | Le Roy-Delage et al. | Aug 2012 | A1 |
| 20120218903 | Baldemair et al. | Aug 2012 | A1 |
| 20130037267 | Regnault De La Mothe et al. | Feb 2013 | A1 |
| 20130048127 | Bosworth et al. | Feb 2013 | A1 |
| 20130062061 | Taylor et al. | Mar 2013 | A1 |
| 20130087333 | Seth et al. | Apr 2013 | A1 |
| 20130126170 | Johnson et al. | May 2013 | A1 |
| 20130140043 | Swanson et al. | Jun 2013 | A1 |
| 20130146286 | Le Roy-Delage et al. | Jun 2013 | A1 |
| 20140020910 | Falkner et al. | Jan 2014 | A1 |
| 20140027129 | Hannegan et al. | Jan 2014 | A1 |
| 20140054043 | O'Malley | Feb 2014 | A1 |
| 20140154497 | Yokota | Jun 2014 | A1 |
| 20150115535 | Trivedi et al. | Apr 2015 | A1 |
| 20150218903 | Sellers, Jr. et al. | Aug 2015 | A1 |
| 20160069482 | Giladi | Mar 2016 | A1 |
| 20160368355 | Richert | Dec 2016 | A1 |
| 20160369436 | Stewart | Dec 2016 | A1 |
| Number | Date | Country |
|---|---|---|
| 1428975 | Dec 2005 | EP |
| 1978071 | Jul 2010 | EP |
| 9403743 | Feb 1994 | WO |
| 2006102171 | Sep 2006 | WO |
| 2010120419 | Oct 2010 | WO |
| 2011133369 | Oct 2011 | WO |
| 2011147021 | Dec 2011 | WO |
| 2012003196 | Jan 2012 | WO |
| 2012094488 | Oct 2012 | WO |
| 2013039774 | Mar 2013 | WO |
| 2013139601 | Sep 2013 | WO |
| Entry |
|---|
| Milberger, et al; “Evolution of Metal Seal Principles and Their Application in Subsea Drilling and Production,” Offshore Technology Conference, May 4, 1992. |
| Ayers, et al; “Effects of Thermal Cycling on Offshore Pipeline Repair Tool Seal Systems,” Offshore Technology Conference, Apr. 30-May 3, 2012. |
| Hitchcook et al., “The Mechanical Response and Anti-Extrusion Characteristics of Fibre-Filled Elastomers”, Journal of Materials:Design and Applications, Volume No. 213, Issue No. 1, pp. 37-46, Jan. 1, 1999. |
| PCT Search Report and Written Opinion issued in connection with corresponding PCT Application No. PCT/US16/060509 dated Feb. 21, 2017. |
| Number | Date | Country | |
|---|---|---|---|
| 20170138147 A1 | May 2017 | US |
