IMPROVED BALL VALVE WITH SMOOTH NECK AND SPLINES LOCATED AT THE BOTTOM OF THE CHAMBER

FIELD OF THE INVENTION

The present invention relates generally to the field of ball valves.

BACKGROUND OF THE INVENMTION

Valves suitable for use in instruments and instrumentation systems are well known. One particularly useful type of valve for these systems comprises a ball valve. Generally, a ball valve includes a chamber or body with an internal valve chamber with inlet and outlet passages.

A ball valve member is disposed within the internal valve chamber. The ball valve member comprises a stainless steel ball positioned centrally within the chamber and a cylindrical valve stem which extends from the ball axially through the chamber to a location outside the body. Packing material surrounds the ball and stem and fills the voids between the ball and the chamber, except for passages which extend from the inlet and outlet passages in the body to the ball. A handle attached to the operating stem allows the ball to be rotated, thereby selectively aligning passages in the ball with the inlet and outlet passages in the body. The ball valve can be a two-way valve with a single inlet and single outlet passage, or a three-way valve with a single inlet and a pair of outlet passages, or a pair of inlet passages and one outlet passage, depending on what the particular application requires.

Two types of ball valves will be interchangeable refers hereinafter as a ball valve, a ball interconnected to a stem, and a trunnion ball valve type, which is a ball integrated with its stem.

US Patent 5,730,420 discloses a ball valve that has a body with a cylindrical bore extending axially inwardly from the exterior of the body and defining a valve chamber. Inlet and outlet passages extend from the exterior of the body inwardly to the chamber. A ball valve member is disposed within the chamber and has an operating stem extending axially within the chamber to a position exterior to the body. A mass of packing material surrounds said ball valve member and substantially fills a portion of the chamber. The packing material initially has a smooth cylindrical outer configuration which matches the cylindrical surface

configuration of the chamber. The body further includes a plurality of splines extending axially along the interior surface of the chamber. The bottom of the chamber is flat. A flat washer and a packing ring are located around the operating stem of the ball the valve member, and a packing nut applies a bias force through the washer to the packing. When the bias force is applied against the packing, the packing ring drives the packing and the packing material within the chamber cold-flows into the splines in the body, so as to prevent rotational displacement of the packing material in said chamber and to reduce leak paths between the mass of packing material and the chamber.

US patent 5,730,420 teaches a packing for the ball valve member, formed in one piece by injection molding the packing around the ball of the ball valve member (i.e., elastic package). Other commercially available valves, e.g., US patent 3,168,900, developed with a one-piece rubber seat or liner surrounding the ball valve which decreases the leak paths around the ball valve, and a single biasing washer which reduces the number of parts necessary for the ball valve.

The splines are provided in a spaced-apart relation in regular intervals along the interior surface of the chamber. The splines are easy to form and extend from the bottom wall of the chamber upwardly for a distance equal at least to the entire axial length of the packing. Preferably, two splines are disposed in each semi-circular half of the chamber at equal distances.

Further, the invention disclosed in '420 necessitates use of a cold-flow process in order to hold the ball pressed tightly in the chamber. Ball valves are disassembled and assembled occasionally for valve's maintenance, decontamination etc. Continued deformation under stress, i.e., cold flow, causes irreversible assembly of the valve, since packaging material is pushed into the splines and cannot subsequently be removed without use of massive force. Moreover, the disassembled valve usually can not be reassembled accurately in its body to its initial configuration, since a portion of the packaging material remains within the splines,

These splines are thus a necessary element in the patent, while the abovementioned ball valve is only operative using them. The splines are splines or thin channels which absorb contaminants and dirt. Further, using cold-flow to assemble the ball-valve makes it difficult to remove the ball from the chamber. A spline-free ball-valve, is less sensitive to contamination due to its smooth interior surface, and is easier to clean than the ball valve disclosed in '420.

A new ball valve free of splines that exceed axially inwardly that is easily detachable for maintenance and cleaning without causing physical deterioration is a long felt need, especially due to the main disadvantage of the cold-flow process used by '420 - its underlying inability to re-assemble all the members of the valve after removal of the ball, since the splines are not completely empty and re-entering the ball may require fixing or even soldering of the valve.

SUMMARY OF THE INVENTION

It is hence in the scope of the present invention to disclose a ball valve comprising a body with a cylindrical bore extending axially inwardly from the exterior of the body and defining a valve chamber, and inlet and outlet passages extending from the exterior of the body inwardly to said chamber; a ball valve member disposed within said chamber with an operating stem extending axially from within said chamber to a position exterior to said body; a mass of packing material surrounding said ball valve member and substantially filling a portion of said chamber, wherein said ball valve comprising a plurality of splines located at the bottom surface of said chamber and define thin splines, said mass of packing material within said chamber interacts with said splines to prevent rotational displacement of said mass of packing material in said chamber and to reduce leak paths between the mass of packing material and the chamber.

The splines of the disclosed ball valve are located at the bottom surface of valve's chamber and not in the cylindrical bore, as previously suggested. Hence, the valve is produced in various manufacturing processes, not essentially by cold flow, the required manufacture process of other commercially available valves, e.g., the valve of US Patent 5,730,420.

It is in the scope of the invention, wherein either the ball is free of elastic packaging or the elastic package is not pushed into splines located at the cylindrical bore.

It is further in the scope of the present invention wherein disassembled valve is reassembled accurately in its body to its initial configuration, unlike the case in commercially available valves, e.g., the one defined in US Patent 5,730,420.

Another advantage of the presently defined ball valve is that the stem and the ball can be removed easily, unlike other valves that require massive force for stem evacuation.

It is known in the art that splines located adjacent to the handle accumulate contaminations. The present invention teaches of a ball valve wherein splines are located away from the

handle, and characterized by a smooth cylindrical bore, being thus insensitive to contamination.

It is another object of the present invention to disclose a ball valve wherein the interior surface of the side walls of said ball valve is smooth and contamination is avoided.

It is another object of the present invention to disclose a ball valve wherein capable of fully and easily re-assemble due to avoiding the cold-flow process while produced.

It is another object of the present invention to disclose a ball valve wherein said splines are provided in the shape of lines.

It is another object of the present invention to disclose a ball valve wherein said lines are randomly designed, without considering any parameters such as precision, size, pattern, or systematic manner, mode or style.

It is another object of the present invention to disclose a ball valve wherein said splines are provided in a shape selected from a group consists of polygonal and ellipsoid, or a combination thereof.

It is another object of the present invention to disclose a ball valve wherein said splines are provided in a curved shape, preferably the shape of a cross or a Saltire.

It is another object of the present invention to disclose a ball valve wherein said splines are provided by physical vapor deposition (PVD) or by chemical vapor deposition (CVD) or by coating at least a portion of said chamber or by keeping the material unpolished or abraded or by chemical etching.

It is another object of the present invention to disclose a ball valve wherein said splines are provided in the shape of curved lines, preferably in the shape of an arrowhead, so as to facilitate the maneuver of the ball.

It is another object of the present invention to disclose a ball valve wherein said arrowhead shape is preferably directed opposite to the direction of the rotation of said ball.

It is another object of the present invention to disclose a ball valve wherein said splines are naturally produced in the bottom of said chamber and/or provided only as part of the manufacture of the chamber.

It is another object of the present invention to disclose a ball valve wherein the lateral cross section shape of said splines is selected from a group consisting of circular or elliptic shape, a polygonal shape, a conic shape, a flat bottom shape, or any combination thereof.

It is another object of the present invention to disclose a ball valve wherein said splines are provided in a variety of depths, in the range of 0.1 -20 mm.

It is another object of the present invention to disclose a ball valve wherein said splines protrude from the bottom of said chamber, towards the direction of the stem.

It is another object of the present invention to disclose a ball valve wherein said splines create a cavity in the bottom of said chamber.

It is another object of the present invention to disclose a ball valve further comprising a handle attached to said stem, such that the rotation of said handle causes rotation of said stem and hence rotation of said ball so that said ball regulates the flow from said inlet to said outlet.

It is another object of the present invention to disclose a ball valve further comprising a gland mounted on said stem; said gland is characterized by a hole in it, where said stem is threaded.

It is another object of the present invention to disclose a ball valve further comprising a packing bolt characterized by a threaded portion where said gland is threaded.

It is another object of the present invention to disclose a ball valve further comprising a panel nut attached to both said handle and said packing bolt.

It is also in the scope of the present invention to disclose a method of producing a ball valve comprising a body with a cylindrical bore extending axially inwardly from the exterior of the body and defining a valve chamber, and inlet and outlet passages extending from the exterior of the body inwardly to said chamber; a ball valve member disposed within said chamber with an operating stem extending axially from within said chamber to a position exterior to said body; a mass of packing material surrounding said ball valve member and substantially filling a portion of said chamber, said ball valve comprising a plurality of splines located at the bottom surface of said chamber and define thin splines, said mass of packing material within said chamber interacts with said splines to prevent rotational displacement of said mass of packing material in said chamber and to reduce leak paths between the mass of packing material and the chamber; wherein said method is free from the step of filling splines with material, hence avoiding the need for cold flow process.

It is another object of the present invention to disclose a method further comprising the step of removing and re-assembling at least a portion of said ball valve, using emptiness of the splines. It is another object of the present invention to disclose a method further comprising the step re-assembling the ball while avoiding the step of fixing and/or soldering the valve.

BRIEF DESCRIPTION OF THE FIGURES

In order to understand the invention and to see how it may be implemented in practice, a plurality of embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which figure 1 shows one embodiment of the novel ball valve; figure 2, shows a lateral cross-section of another embodiment of the novel ball valve; figure 3, shows the chamber of the valve without one of the corners of said chamber; figure 4, shows an uppercase section of the chamber; figure 5, schematically shows a external of the valve; figure 6, schematically shows a cross-section of the valve. figures 7-12 schematically show the an uppercase out of scale illustration of splines; figures 13-14 show lateral sections of the splines; figures 15 A, 15B schematically show an out of scale illustration of a ball valve; figures 16A, 16B schematically show a disjoined illustration of the same; figure 17 schematically shows a side view of the same, defining in an out of scale presentation the location of the spline (91) inside the chamber; and. figure 18 schematically shows a 3D illustration of the same (without showing the location of the spline).

DEATILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description is provided, alongside all chapters of the present invention, so as to enable any person skilled in the art to make use of said invention and sets forth the best modes contemplated by the inventor of carrying out this invention. Various modifications, however, will remain apparent to those skilled in the art, since the generic principles of the present invention have been defined specifically to provide a ball valve with a body comprising inter alia at least one spline, defining thin splines located at the bottom portion of

said chamber so that the portions of the interior surface extending axially (parallel to a stem exceeding from the ball located in the passageway to the upper portion of the body, where a handle is to be provided) are smooth (i.e., essentially comprising no splines), said mass of packing material within said chamber interacts with said splines to prevent rotational displacement of said mass of packing material in said chamber and to reduce leak paths between the mass of packing material and the chamber.

The term 'ball valve' refers hereinafter to a valve that is opened by turning a handle attached to a ball inside the valve. The ball has a hole, or port, through the middle so that when the port is in line with both ends of the valve, flow will occur. When the valve is closed, the hole is perpendicular to the ends of the valve, and flow is blocked. The handle position enables an onlooker to determine the valve's position.

The term 'chamber' refers hereinafter to the material surrounding the cylindrical bore in which the stem and the ball are located. The chamber is preferably composed of an elongated portion with interior cylindrical shape, attached to a square member in which the ball is located.

The term 'spline' refers hereinafter to a material or lack of material that renders the surface unsmooth. In the present invention, the surface is the wall in the bottom of the chamber. The splines can be thin channels, and/or grooves and/or strips, in any shape, and can be a cavity in the bottom of the chamber or protrude from the surface.

The present invention specifically relates to a ball valve, comprising in a non-limiting manner: a. a body with a cylindrical bore extending axially inwardly from the exterior of the body and defining a valve chamber, and inlet and outlet passages extending from the exterior of the body inwardly to said chamber; b. a ball valve member disposed within said chamber with an operating stem extending axially within said chamber to a position exterior to said body; c. a mass of plastic packing material surrounding said ball valve member and substantially filling a portion of said chamber, said mass of packing material has an exterior surface diameter which is substantially the same as an interior surface diameter of said chamber, said body further including a plurality of splines defining thin splines located at the bottom portion of said chamber so that that the portions of the interior surface extending axially (parallel to said stem) are smooth (i.e., essentially comprising no splines), said mass of packing material within said chamber interacts with said splines to prevent rotational

displacement of said mass of packing material in said chamber and to reduce leak paths between the mass of packing material and the chamber.

Reference is now made to figure 1, showing one embodiment of the novel ball valve. In the figure, a part of the chamber (14) is missing, so as to show a cylindrical bore surrounded the chamber. A stem (17) is located inside said bore, and can rotate over the longitudinal axis of the bore. The stem 17 is attached to a ball, which regulates the flow from the inlet (12) to the outlet (13) of the valve. Said stem 17 is also connected to a handle (11), so that the user can regulate the flow in the valve. The cylindrical bore is smooth and has no splines or splines or channels, so as to facilitate removal of the stem for cleaning, or to avoid contamination in the bore or in the passageway between the inlet and the outlet. The ball touches the bottom of the bore while the stem rotates, and hence said bottom is not flat, to avoid wear to said ball. The form of the channels or splines in the bottom is further detailed.

Reference is now made to figure 2, showing a lateral cross-section of another embodiment of the novel ball valve. The figure shows more clearly the passageway (24) which leads the fluid from the inlet (22) to the outlet (23) of the valve. It is also shown that the chamber (21) surrounds the bore (25) and is located on top of both inlet (22) and outlet (23). The splines (26) are located at the bottom of the bore, on top of the passageway (24). Neither the stem located in the bore nor the balls located in the passageway are shown in this figure.

Reference is now made to figure 3, showing the chamber of the valve without one of the corners of said chamber, so as to illustrate the internal portions of the valve and the relations thereof. The passageway is clearly shown here with two of its portions, both connected to the bore, where the ball regulates the flow from the inlet to the outlet. The first portion of the passageway (32) leads the fluid from the inlet to the ball, and the second portion of the passageway (34) leads the fluid from the ball to the outlet. The cylindrical bore (33) is located in the chamber (31) and its bottom portion (35) contains splines (36), unlike the walls of said bore, extending upwardly parallelly to the longitudinal axis of the bore, which are smooth.

Reference is now made to figure 4, showing an uppercase section of the chamber (43), with said cylindrical bore (47) inside it. At least one spline (44) is located at the bottom of said bore. An inlet (41) and outlet (47) are connected by a first portion of a passageway (42) and a second portion of a passageway (45).

Reference is now made to figure 5, schematically showing a lateral cross section of the valve. It is clearly shown that the longitudinal axis (52) of the bore is perpendicular to the longitudinal axis (53) of the passageway, so as to maximize the ball's pressure on the passageway and to maximally regulate the flow in said passageway.

Reference is now made to figure 6, schematically showing a cross-section of the valve. The handle (68) is connected to the stem (64) using a connecting means (65). Said stem is located inside a cylindrical bore (63) and is capable of rotating in the bore. A ball (62) attached to one end of the stem rotates when the stem rotates, and regulates the flow of fluid in the passageway from the inlet (67) to the outlet (66).

Reference is now made to figure 7, showing one embodiment of the spline located at the bottom of the chamber. One or more splines are provided at the bottom, in the shape of lines, regardless of any precise or systematic manner, mode or style.

Reference is now made to figure 8, showing one embodiment of the spline located at the bottom of the chamber. According to one embodiment, one or more splines are provided in an ellipsoid shape, polygonal shape, or a combination thereof.

Reference is now made to figure 9, showing one embodiment of the spline located at the bottom of the chamber. In this embodiment, one or more splines are provided in a curved shape, preferably the shape of a cross or a Saltire.

Reference is now made to figure 10, showing one embodiment of the spline located at the bottom of the chamber. In this embodiment, the splines are provided by physical vapor deposition (PVD) or by chemical vapor deposition (CVD) or by coating a portion of said chamber or by chemical etching.

Reference is now made to figure 11, showing one embodiment of the spline located at the bottom of the chamber. The splines are provided in the shape of a curved line, preferably in the shape of an arrowhead, so as to facilitate the maneuver of the ball located in the chamber. Said arrowhead shape is preferably directed opposite to the direction of the rotation of said ball.

Reference is now made to figure 12, showing splines that are unprocessed and are provided only by the manufacture of the chamber.

Reference is now made to figure 13, showing a lateral cross section of the splines, along with the bottom surface (88) of the ball valve. The figure describes a plurality of shapes by which

the splines are provided. For example, a circular or elliptic shape (82), a polygonal shape (84), a conic shape (80), a flat bottom shape (86), or any combination thereof.

Reference is now made to figure 14, showing a lateral cross section of the splines. It is shown that the splines may be provided in different depths, and also sometimes protrude from the chamber bottom.

Reference is now made to figures 15 A, 15B, showing (lateral cross section, top view) according to one embodiment of the present invention, comprising at least one spline (91) located at the bottom portion of the chamber (3), and a smooth cylindrical bore (7) with no splines. The components described are the handle (9), set screw (10), which facilitates rotation on the rotation of the ball (2), the bore (5), side ring (4), gland (6). the chamber (1 ), and the panel nut (8).

Reference is now made to figures 16A, 16B, showing a disjoined illustration of the ball valve. The figure shows the handle (9), the panel nut (8) which attaches the handle to the thread of the packing bolt (7), which in turn attaches to a gland (6) that is located on a stem (2). Said stem is attached to a ball (3) with at least one seat (14), at least one of said seats is mounted on a seat ring (4). Said ball is located inside the chamber (1). A zoom-in figure of the stem with the cylindrical bore is provided (12).

Reference is now made to figure 17, schematically showing a side view of the same, defining an out of scale presentation of the location of the spline (91) inside the chamber. Reference is now made to figure 18, schematically showing a 3D illustration of the same (without showing the location of the spline).