CROSS-REFERENCE TO RELATED APPLICATIONS

0001 This application claims priority to IXS. Patent Application serial number j 5/719,273, entitled "in Situ Gasket Assembly" and filed September 28, 2017, which is a continuation-iti-pan of U.S. Patent Application Serial No. 15/471,950, entitled "Gasket Seal Seat Ring" and filed March 28, 2017, which claims the benefit of U.S. Provisional Patent Application Serial No. 62/318,827, entitled "Gasket Sea! Seat Ring" and filed on April 6, 2016. The entire disclosures of both documents are incorporated herein in their entirety.

BACKGROUND

[0002] Valve designs can employ multiple methods of installation of the sealing element in their design. High performance double offset valves generally hold the sealing elemen between, the primary body section and a secondar removable seat retainer. This joint connection must be sealed, or leakage between the body and seat retainer ring ma occur. In "end of line service" the seat retainer ring must hold the rated differential of the valve without support from ^' the low pressure side mating flange. Accurate placement of the seal between the two components, seal integrity during handling and an efficient assembly process are essential.

SUMMARY OF THE INVENTION

[0003] Industry standards and market-driven pressure for design efficiency have pushed valve designers to try and seal with smaller surface areas. The proposed device allows for an initial sealing media (e.g., gasket) to be applied to moltiple sealing planes within a pressure system and allows for sealing media to adjust to geometric differences within the pressure system. Using the fragile sealing material handling and transport strategies disclosed herein, embodiments within the scope of the present disclosure may produce seal dimensions that are smaller thaji current traditional.. methods of sealing.

[0004] Some embodiments of the invention provide a valve. The valve has a body having a channel extending through the valve and a first sealing surface and a second sealing surface each positioned radially outward from the channel and offset from one another. The offset between the first sealing surface and the second sealing surface defines a bore, A valve element .may be positioned within the channel and may be configured to selectively inhibit flow through the body. A gasket may abut a portion of the first sealing surface and a portion of the second surface. In some embodiments, a cutter seat is at least partially received within the bore and is configured to compressively engage the second sealing surface. The cutter seat may comprise a cutter that is configured to create a first sub-gasket and a second sub-gasket by severing the gasket during installation. A retaining ring ma be coupled to the valve body. The retaining ring may comprise a first mating surface and a second mating surface, where the first mating surface is configured to compressively engage the first, sob-gasket, and the first, sealing surface of the body, while the second mating surface is configured to compressively engage the cutter seat, second sub- gasket and second sealing surface.

{0005} In some embodiments, the cutter comprises a sharpened edge and a flat mating surface. The sharpened edge may be configured to shear a unitary gasket into at least the first and second sub-gaskets. The flat surface may be configured to compressively engage the second sealing surface of the body. In some embodiments, the sharpened edge of the cutter extends forwardly beyond the flat mating surface of the cutter seat. The sharpened edge ma contact the unitary gasket, during, installation of the cutter seat into the bore ^' before the flat mating, surface of the cutter seat contacts the unitary gasket. In some embodiments, the second sealing surface of the body comprises a channel extending into a portion of the second sealing surface to accommodate the cutter of the cutter assembly.

[00061 In some embodiments, the cutter may further comprise a gasket trap. The gasket trap may be formed- of two surfaces extending inwardly from the sharpened edge and the flat mating surface, and may form an angle between about 30° and abou 150°. In some embodiments, a. portion of the second sealing surface of the body extends into the gasket trap to define an approximately v-shaped cavity between the cutter seat and the body, and the v-shaped cavity is configured to extrude the second sub-gasket into an approximately v-shaped cross-section when the second sub-gasket is compressed between the cutter seat and the body.

- - (§0§7| in some embodiments, the second sealing surface of the body comprises one or more grooves extendma into the second sealing surface- and the one or more roo s axe confiaured to selectively compress a portion of the second sub-gasket jOO08| la some embodiments, a portion of the second sealing surface of the body is configured to compressive^ engage a soft seat. The soft seat may be formed of a material selected from the group consisting of reinforced tetrafluoroethyleae ( TFE) and reinforced polytettaflueroeth iene ( PTFE). In some embodiments, the cutter seat comprises a sealing portion extending radially inward into a portion of tlie channel, and tlie sealing portion is configured to engage and disengage a disk of the valve during operation.

[0009] Some embodiments of the invention provide a valve. The valve may comprise a valve body having channel extending there through. A graphite gasket ma be configured to be received on a first surface of the valve body. The first surface of the valve body may ex tend radially outward from the channel The valve further comprises a cutter seat comprising a cutter configured to sever the graphite gasket int at least a first annular sub-gasket and a second annular sub-gasket by compressively contacting the graphite gasket with a sharpened edge. The cuiter seat may be configured to engage a second surface of the valve body. The second surface of the valve body may extend radially outward from the channel and may be inwardly offset from the first surface of the valve body. The valve may further comprise a seat retaining ring configured to compress the first surface of the valve body, the graphite gasket, and the cutter seat.

[0010] In some embodiments, the cutter seat comprises a mating surface configured to abut against the second surface of the valve body, and the sharpened edge may extend forward!}' beyond the mating surface. A channel may extend through a portion of the second sealin surfac of the valve body to receive a portion of the cutter.

100111 In some embodiments, the cutter seat comprises a sealing portion configured to engage and disengage a disk of the valve. The sealing portion may have an arcuate shape extending radially inward from an outer surface of the cotter seat. In some embodiments, the cutte comprises a gasket trap formed of two angled surfaces extending inwardly from th sharpened edge and the mating surface, in some embodiments, these surfaces form an angle between about 60° and about 120°, I some embodimen s, the valve further comprises a soft seat configured to abut against the second surface of the valve body and the cutter seat.

{0012] in some embodiments, a method of forming a multiple-plane seal within a valve assembl is provided. The method may comprise the step of providing a valve body. The valve body may have a channel extending there through, a first surface positioned radially outward from, the channel, and a second surface located radially and axially inward from the first surface, so that the offset between the first surface and the second surface defines a cylindrical bore. The method may further comprise the step of positioning a gasket on the first surface of the valve body so that a portion of the gasket extends radially inward beyond the first surface to cover a portion of the cylindrical bore. In some embodiments, the method may further comprise urging a cutting element into the cylindrical bore towards the second surface of the valve body. The cutting element may provide a sharpened edge approximately adjacent to a circumferential surface of the cylindrical bore, thereby cutting the portion of the gasket extending radially inward beyond the first surface of the valve body to form at least two annular sub-gaskets. The first, sub-gasket may reside on the first surface of the valve body and the second sub-gasket may reside on the second surface of the valve body. The method may further comprise coupling a retaining ring to the valve body .in a way that causes the retaining ring to compress ^' the first sub- gasket between a first surface of the retaining ring and the first surface of the valve body and in a way that compresses the second sub-gasket, between the cutting element and the second surface o the valve body.

[0013] In some embodiments, the gasket, valve body first surface, valve body second surface, and cutting element are all positioned substantiall concentric with the channel extending thro ugh the valve body. j001 | in some embodiments, the cutting element is formed, integrally as part of a metal cutter seat having an outer surface defined by a radius slightly smaller in size than the radius defining the cylindrical bore.

[0015} in some embodiments, the step of coupling the retaining ring to the valve body is performed b threading a · plurality Of fasteners- through the retaining ring into a plurality of threaded holes in the valve body. (§016 J These and other features of the present disclosure will become more apparent from the following description of the illustrative embodiments.

BRIEF DESCRIPTIO OF DRAWINGS

[Θ017| FIG. 1 is a perspective view of a butterfl valve according to one embodiment of the inv ention.

[00 J 8| FIG. 2 is art exploded view of the butterfly valve of FIG. .1.

[0019| FIG. 3 is a top, front perspective view -of a retaining ring of the butterfly valve of FIG. 1.

[00201 FIG. 4 is top, rear perspective view of the retaining ring of FIG. 3,

{0021 J FIG. 5 is a sectional view of the retaining ring taken along the line 5-5 of FIG. 4.

[00221 FIG. 6 is a top, front perspective view of a body gasket of the butterfly valve of FIG. 1.

[00231 FIG. 7 is a sectional view of the body gasket taken alon line 7- 7 of FIG, 6.

109241 FIG. 8 is a top, front perspective view of a metal seat of the- butterfly valve ^' of FIG. I.

[00251 FIG. 9 is a sectional view of the metal seat taken along line 9-9 of FIG. 8,

(00261 FIG. i 0 is a top, front perspective view of a soft seat of the butterfly valve of FIG. 1.

(00271 FIG. Π is a sectional view of the soft seat taken along line 1 1 -1 1 of FIG. 10.

(00281 FIG. 12 is a top, front perspecti ve view of a disk of the butterfly valve of FIG. 1.

(00291 PIG. 13 is top, front perspective vie w of a body of the butterfly valve of FIG, 1.

[00301 FIG. 14 is a sectional view of the body taken along line 14-14 of FIG. 13.

[00311 ¥IG. 15 is a sectional view of the butterfly valve taken along line 15-15 of FIG. 1. (§032J FIG. .16 is a detail view of the butterfly valve taken within circle 16-16 of FIG. 15.

|0033| FIG. 17 is a front view of a butterfly valve according to another .embodiment.

[0034} FIG. 18 is a sectional view of the butterfly valve taken along line 18-18 of FIG. 17.

[0035} FIG. 19 is a detail view of the butterfly valve taken within circle 19-19 of FIG. 18.

[0036} FIG. 20 is a front view of a body gasket according to another embodiment. 0037| FIG. 2.1 is a body gasket according to yet another embodiment.

[0038} FiG, 22 is a front view of a retainin ring according to another embodiment.

[0039J FIG. 23 i a sectional view of the retaining ring taken along line 23-23 of FIG. 22.

[0048} FIG. 24 is a detail view of the retaining ring taken within tine 24-24,

[0041} FIG. 25 is a detailed sectional view of a cutting profile of a retaining _, ring according to one embodiment.

[0042} FIG. 26 is a detailed sectional, view of a cutting profile applied to a retaining ring according to another embodiment.

[00431 FIG. 27 is a detailed sectional view of a. catling profile applied to a. retaining ring according to yet another embodiment

[0044] FIG. 28 is a detailed sectional view of a butterfly valve according to yet another embodiment.

[0045} FIG. 29 is a perspective view of butterfly valve in accordance with another embodiment of the present disclosure.

[0046} FIG. 30 is an exploded view of the butterfly val e of FIG. 29. [0047} FIG. 31 A is a front view of the butterfly valve of FIG, 29. (§048 J FIG . 3 IB is a. cross-sectional view of the butterfly valve of FIG. 29 taken along lines

31B~31B ra FIG. 31 A,

[0049] FIG, 31C is a detailed sectional view of a sealing assembly of the butterfly valve of FIG. 29 taken along circular section 31C in FIG. 31 B.

[0050] FIG, 32 A is a perspective section view of the sealing assembly utilized in a butterfly valve according to another embodiment of the present ^■ disclosure.

[0051] FIG. 32B is a perspective section view of the sealing assembly utilized in another embodiment of the present disclosure.

[00521 FIG. 32C is a perspective section view of the sealing assembly utilized in another embodiment of the present disclosure.

[00531 FIG. 32D is a perspective section view of the sealing assembly utilized- in yet another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[00541 Before any embodiments of the invention are explained in detail, it i to be understood that the invention is not limited in its applicatio to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herei is for the purpose of descriptio and should not be regarded as limiting. The use of "including," "comprising " or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms "mounted," "connected," ''supported," and "coupled" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings.

[0 551 The following _, discussion is presented to enable a person skilled in the ^■ art. to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can he applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

£005fi| FIG. 1 shows -a butterfly valve 50 that includes a body 54,. a disk 58 rotatahle between an open posi tion and a closed position -for- selectively providing and inhibiting flow along a flow axis 60, a shaft 62 coupled to the disk 58 to cause rotation of the disk 58, and a sealing assembly 66. The butterfly valve 50 may be used for controlling the flow of fluids or gases. As shown in FIG. 2, the sealing assembly 66 includes a retaining ring 70, a body gasket 74, a metal seat 78, and a soli seat 82. Multiple arrangements of seats 78 and 82 are potentially available for end user selection. Fasteners 84 ma couple the sealing assembly 66 to the bod 54. Various arrangements of fasteners 84 ma be present as valve 50 design requirements change. For example, the fasteners 84 may be screws, bolts., clips, clamps, or any other suitable fastening mechanism. Still further, the fasteners 84 need not all be the same. O0S7) As shown in FIGS. 3 and 4, the retaining ring 70 includes a plurality of eounterbored through-holes 86 that are arranged to facilitate fastening the sealing assembly 66 to the body 54, however, depending on the design, these are not necessaril present. With referenc to FIG. 5, the retaining ring 70 includes a primary ring gasket seat sealing surface 90, a cutter 94 _s a secondary ring gasket seat sealing surface 98, and a metal stop 102. The primary ring gasket seat sealing surface 90 defines a primary seat plane 106 and is substantially flat. In other embodiments, the primary ring gasket seat sealing surface 90 may define a shaped profile (e.g., a frustoconica!. or curved profile). The cutter 94 is arranged between the primary ring gasket seat, sealing surface 90 and the secondary ring gasket seat sealing surface 98 and may define a sharpened edge 1 10, a flat wall 3 14, and a sloped wall 1 18. The secondary ring gasket seat sealing surface 98 may define a secondary seat plane 322 spaced apart from the primary seat plane 106 axially along the flow axis 60, A seat width 126 is defined between the ring shoulder 102 and outer periphery of the primary ring gasket seat sealing surface 90.

[0058) As shown m FIG 6, the body gasket 74 is annular and may include apertures 130 arranged to align with the through-holes 86 formed in the retaining ting 70. With reference to FIG. 7, the body gasket 74 defines a gasket width 134 that is sized to be at least as wide as the seat width 126 of the retaining ring 70. The body gasket 74 also defines a gasket thickness 138.

[0059} As shown in FIG, 8, the metal seat 78 is annular and may be formed out of stamped metal With reference to FIG, 9, the metal seat 78 includes a metal flange 142 and a metal sealing portion .146. The metal seat 78 is flexible enough to engage and disengage the disk 58 during operation of the butterfly valve 50. In one embodiment, the seat 78 is formed from metal.

[00601 As shown in FIG. 10, the soft seat 82 is annular and may he formed of a plastic or polymeric material With reference to FIG. 1 1, the soft seat 82 includes a head portion 150 and a sealing surface 154 arranged to engage and disengage the disk 58 during operation of the butterfly valve 50. In one embodiment, the soft seat 82 is formed from PTFE plastic.

[0061 As shown in FIG, 12, the disk 58 includes a shaft aperture 158 sized to receive the shaft 62, a metal sealing portion 162 arranged to selectively engage the metal seat 78, and a soft sealing portion 1 6 arranged to selecti vely engage the soft seat 82.

[0062J As shown in FIG. 13, the body 54 includes a body shaft aperture 170 sized to receive the shaft 62 and aligned with the shaft aperture 158, and further includes a seal recess 174. With reference to FIG. 14, the seal recess 174 is defined by a body shoulder 178, a primar body gasket seat 182, a shearing wall 1 4, an anvil surface 186. a clamping portion 1 0, and a soft seat portion .1 4. The body shoulder 178 defines a body shoulder height 1 8 that is sized relative to the body gasket 74 to provide a predetermined degree of compression. The primary body gasket seat 182 defines a primary body seat width 200. The anvil surface 186 defines a flat, solid surface and is arranged to interact with the cutter 94, The clamping portion 190 defines a textured surface in the form of grooves which may or may not be required for the functionality of the design. (§063| As shows in FIG. 15, the assembled butterfl valve 50 inhibits fluid flow past the disk 58 when in the closed position. The shaft 62 can be actuated to move the disk 58 between the open position and the closed position.

1006 ] FIG. 16 illustrates the assembly of the butterfly valve 50. The soft seat 82 is first placed into the seal recess 174 abutting the soft seat portion 194 of the body 54. Then, the metal seat 78 is inserted such that the metal flange 142 abuts the clamping portion 1 0 of the body 54 and the soft seat 82 is captured between the metal seat 78 and the soft seat portion 1 4. The body gasket 74 is then inserted into the seal recess 174 radially inside the body shoulder 178 as a single piece, as shown in FIG, 6. When fist inserted, the body gasket 74 extends radially beyond the shearing wall 184 in an inward direction. That is. to say, the gasket width 134 is larger than the- primary body seat width 200, as shown in FIG. 14, With the body gasket 74 seated, the retaining ring 70 is inserted into the seal recess 174 such that the cutter 94 engages the body gasket 74 adjacent the shearing wall 184. Load is applied either via fasteners or machine resulting in the cutter 94 and the shearing wall 184 cooperating to cleanly cut the body gasket 74 into a primary portio 74A and an inner secondary portion 74B. If present, the fasteners 84 are tightened to a predetermined torque that results in the outer portions of the primary ring gasket seat sealing surface 90 of the retaining ring 70 making hard contact with the body shoulder 178. This hard contact provides a predetermined compression of the body gasket 74, Additionally, the metal ring 102 of the retaining ring 70 makes hard contact with the metal flange 142, compressing the metal flange 142 between the clamping portion 190 of the body 54 and the ring shoulder 102. When fully tightened, the primary portion 74 A is compressed between the primary ring gasket seat sealing surface 90 and the primary body gasket seat 182, and the secondary portion 74B is compressed between the secondary ring gasket seat sealing surface 98. the anvil portion 186, the metal flange 142, and the metal ring 102, The secondary portion 74B is deformed during the tightening process to fill in any voids.

(0065f The arrangement of the body shoulder 178 and the ring shoulder 102 provide a predetermined compression of the body gasket. 74 and inhibit overtightenmg/overcompression.

10066] In some embodiments, the primary seal portion 74A may have a width Wl (FIG. 1 } that is greater than a width W2 of the secondary seal portio 74B. In other embodiments, the widths Wl , W2 may be the same or Wl may be less than W2. In some embodiments, the body gasket ma be a non- laminated graphite gasket.

[0067] FIGS, J 7-19 show another butterfly valve 50' that is similar to the butterfly valve 50 discussed above.

[0068] FIG, 20 shows a body gasket 210 that defines an outer diameter 214 of about forty inches (40") and a _. gasket width 218 of about Wo and forty-five hundredths inches (2 ,45"). This is a standard size for a thirty-six inch gasket,

[0069) FIG, 2.1 shows body gasket 222 that defines an outer diameter 226 of about six inches (€") and a gasket width 230 of about sixty-six hundredths inches (0.66"}, This is a standard size for a four-inch gasket. Both of the gaskets of FIGS, 20 and 21 are examples of gaskets that may be used with the above described embodiments io provide a cut-dming- installation, self-centered,, two-plane body gasket.

[0070| FIGS. 22-24 show another retainer ring 234 that includes cutter 238, sealing surfaces 242, and a sealing plane offset 246 of about six hundredths of an inch (0.06").

[00711 FIGS. 25-27 illustrat different cutter profiles 300a, 300b _? 300c that include a straight slope, a curved slope, and grooves o teeth formed in the slope, respectively. One skilled i the art will understand that any of the cutter profiles disclosed herei ma be utilized with any of the embodiments described herein.

[Θ072] FIG, 28 shows another retaining ring 370 that .includes a cutter 394 that is a separate component and not formed as a part of the retaining ring 370. The assembly of FIG. 28 is assembled in the same manner as described with respect to FIG. 16 and generally includes the same components and features of FIGS, 1-16 _» excep that the cutter is a separate component. In this manner, the cutter 394 may be placed against the retaining ring 370 or may attached to the retaining ring 370, for example, by an adhesive or any other suitable attachment mechanism.

[0073] Referring to FIG. 29, a further embodiment of a butterfly valve 450 is shown. Similar to the butterfly valves shown and discussed with reference to FIGS, 1-28, the butterfly valve 450 includes a valve body 454 and a disk 458 rotatahle between an open position and a closed

- 1 ί ~ position for selectively providing and inhibiting flow along a flow axis 460 through a central channel 434. A shaft 462 may be coupled to the disk 458, wherein the shaft 462 may be rotated relative to the valve body 454, which in turn causes the disk 458 to rotate between the closed and open positions, thereby controlling the flow of fluid through the central channel 434 of the butterfly valve 450, A sealing assembly 466 inhibits flow when the disk 458 is in the closed position, and also restricts leakage outward from the butterfly valve body 454,

[Θ0741 Referring now to FIG, 30, the sealing assembly 466 is shown in greater detail. I some embodiments, the valve body 454 of butterfly valve 450 is configured to receive a gasket 474, which can be used to provide sealing o multiple surfaces. In some embodiments, this gasket may comprise a ooacombustibk material, such as graphite. As will be explained in further detail below, the gasket 474 may be provided with a brittle material that allows the gasket 474 to be severed into a plurality of different gaskets (not shown), which may allow gasket 474 sealing on at least two surfaces (e.g., two surfaces that are spaced apart along the flow axis 460). The body 454 can be provided with a plurality of mating surfaces that may be configured to receive the gasket 474 to provide sealing between the valve body 454, the cutter seat 478, and. a seat retaining rins 470.

[00751 Jft some embodiments, the butterfly valve 450 includes a cutter seat 478, which may be separate and distinct from the seat retaining ring 470. Similar to the metal seat 78 discussed above in FIG. 9, the cutter seat 478 may be formed of a suitable metal (e.g. 304 stainless steel, 316 stainless steel aluminum, or another suitable material or materials) and may include a flange 448 and a sealing portion 446 (shown in FIG. 3 IC), as discussed in more detail below. By including a cutter seat 478 separate from the seat retaining ring 470, a standardized seat retaining ring 470 may be used in the butterfly valve 450 that may allow one universal seat retaining ring 470 design to be used across multiple different butterfly valve 450 applications. For example, the same seat retaining ring 470 may be used in low-temperature applications that may not require "firesafe" sealing. The design of the seat retaining ring 470 ma allow the butterfly valve 450 to utilize elastomeric, polymeric, or other suitable gasket materials to provide sealing withi the butterfly valve 450. In some embodiments, a plurality of fasteners 484 are used, to couple the sealing assembly 466 to the valve body 454, Fasteners 484 may be configured to extend through counterbored holes in the seat retaining ring 470, and thread into holes present in the valve body 454, in some embodiments, th fasteners 484 compress the seat retaining ring 470, the cutter seat 478. the gasket 474, and the val ve body 454 together, such that a substantially leak-free seal is formed between the components. It should be appreeiaied, however, that man other types of fasteners may be used to fasten the sealing assembly 466 to the valve body 454, such as any of the fasteners discussed above with reference to FIGS. .1 and 2, for example. 0076J With further reference to FIGS. 3 IB and 3IC, the mating of sealing surfaces in the sealing assembly 466 is shown in greater detail. In order to better understand the functionality of components in the butterfly valve 450, a method of installing the components of the sealing assembly 466 will be described, in some embodiments, valve body 454 is provided with a plurality of mating surfaces 482, 486, which are adapted to form compressive contact betwee one or more components. The mating ^' surfaces 482, 486 may be substantially flat surfaces, and may also include a plurality of grooves 488, In some embodiments, the grooves 488 are provided to restrict fluid from moving outward away from the mating surfaces 482, 486 towards an external environment, such as an outer surface of butterfly valve 450, The grooves 488 may also be a retaining feature, and can be designed to engage and restrict movement of a soft seat that may be present in some embodiments of the butterfly valve 450 which are adapted for lower temperature applications,

{øø??! in some embodiments, the valve body 454 is provided with a substantially cylindrical bore 490 that is configured to at least partially receive one or more additional sealing components, such as the gasket 474 and/or the cutter seat 478. In some embodiments, the cylindrical bore 490 is defined by a radius that is sized to be slightly larger (e.g. between about 0.05 mm and about 10 mm) than a radius defining an outer surface 444 of the cutter seat 478, such that a tight clearance fit can be created between the cylindrical bore 490 and the outer surface 444 of the cutter seat 478. In other embodiments, the radius defining the cylindrical bore 490 is chosen to be approximately equal in length to the radius defining the outer surface 444 of the cutter seat 478, such that an interference fit can be created between the outer surface 444 of the cutter seat. 478 and the cylindrical bore 490 of the valve bod 454.

{00781 As indicated above with reference to FIGS. 29-30, the gasket 474 may be present in the sealing assembly 466. In some embodiments, the gasket 474 comprises a brittle material such as graphite or carbon fi er. The gasket 474 may be provided with an annular shape, such as that described with reference to body gasket 74 in FIGS. 6 and 7. in some embodiments, the gasket 474 is designed to sit upon the mating surface 482 of the valve body 454 during installation in the butterfly valve 450. The mating surface 482 may be sized and shaped to help locate the gasket 474 within the proper location relative io valve body 454 during installation. For example, the mating surface 482 may be partially defined by an outer radius (not shown) that is slightly larger in size than the radius defining the outer surface of gasket 474 (e.g. between about 0.05 mm and about 10 mm). By providing a small clearance between the outer surface of the gasket 474 and the outer boundary of the mating surface 482, the gasket. 474 can be appropriately positioned substantially concentrically with the central channel 434 extendin through valve body 454. In some embodiments, the inner radius of the gasket 474 is defined by a radius that is smaller than the radius defining the cylindrical bore 490 of the valve body 454, such that a portion of the gasket 474 extends radially inward from and covers a portion of the cylindrical bore 490 when the gasket 474 is seated on the mating surface 482, prior to installation of the cutter seat 478. As discussed below, this allows the gasket 474 to be severed into a pluralit of sub-gaskets 474A, 474B and. provides sealing on multiple mating surfaces 482, 486 once the cutter seat 478 and the seat retaining ring 470 are installed.

|0079| The gasket 474 may comprise a brittle material that can be configured to shear into a plurality of different sub-gaskets 474.A, 474B when a sufficient compressive force is applied to a surface of the gasket 474. These sub-gaskets 474A, 474B may then be used to seal multiple different surfaces in the butterfly valve 450, which may be particularly advantageous in some applications. 0080 In some embodiments of the assembly and installation process of the sealing components 466 into butterfly valve 450, the gasket 474 is first placed onto the mating surface 482 of the valve body 454, As indicated previously, the size and shape of the gasket 474 and the mating surface 482 allow the gasket 474 to be easily positioned in a proper location relative to the valve body 454 (i.e. substantially concentric with the central channel 434 of the valve body 454). As discussed earlier, a portion of the gasket 474 may then extend inwardly over a portion of the cylindrical bore 490 of the valve body 454. A cutter seat 478 may then be urged into the cylindrical bore 490 of the valve body 454, If the gasket 474 comprises a brittle material the gasket 474 will shear along an area between the outer surface of the cutter seat 444 and the surface of the cylindrical bore 490, such that, gasket 474 is split into at least two sub-gaskets 474A, 474B capable of sealing two different surfaces. For example, the sub-gasket 474A may be configured to provide a seal between the cutter seat 478 and the valve body 454, while the sub- gasket 474B may be configured to provide a seal between valve body 454 and seat retaining ring 470.

[Θ0811 To improve the shearing process of the gasket 474, the cutter seat 478 may be provided with a cutter 436 that defines a sharpened edge 438 designed to produce a shearing plane corresponding to the outer surfac 444 of the .cutter seat 478. in some ^■ embodiments, the cutter 436 extends forwardly beyond fiat, mating surface 439 of the cutter seat 478. Accordingly, when the cutter seat 478 is assembled into place (after the gasket 474 has been positioned properly relative to valve body 454), the first point of contact between the cutter seat 478 and the gasket 474 occurs at sharpened edge 438. As the cotter seat 478 is urged further into the cylindrical bore 490 of valve body 454, the sharpened, edge 438 projects a concentrated force to the gasket 474 along the point, of contact, between sharpened edge 438 and the gasket 474. Because a portion of the gasket 474 extends inwardly over the cylindrical bore 490 of the valve body 454, this concentrated force is unopposed by the valve body 454. and causes the gasket 474 to shear cleanly along a plane defined by the sharpened edge 438 and the outer surface 444 of the cutter seat 478. j0082| In order to produce a seal between the cutter seat 478 and the valve body 454, a number of different features may be utili ed. For example, valve body 454 may be provided with a channel 441 that extends into the mating surface 486 of the valve body 454 t accommodate the tooth-like shape of the cutter 436. In. some emb dim nts, the cutter 436 is provided with a gasket trap 440 designed to produce compressive engagement between the gasket 474, the cutter seat 478, and the valve body 454. As the gasket 474 is being sheared, the gasket trap 440 is designed to restrict radial movement of the gasket 474 relative to the cutter seat 478 by capturing the gasket 474 within its two angled surfaces. In some embodiments, the angled surfaces of the gasket trap 440 form an angle of between about 10° and about 170°, or between about 30° and about 150°, or between about 60° and about 120°, in some embodiments, the angled surfaces of the gasket trap 440 form an angle of about 90°. (§083J The shape and location of the one of .more grooves 488 on mating surface 486 of the val ve body 454 may be positioned to farther manipulate the shape of gasket 474 once it has bee sheared into the sub-gaskets 474A, 474B. For example, the one or more grooves 488 may be offset such that the mating surface 486 of the valve body 454 extends at least partially into the gasket trap 440, as shown in FIGS. 31B and 31 C. If the gasket 474 comprises a brittle material., the gasket 474 may be readily deformed by the geometry of the gasket trap 440 and the grooves 488 to produce an effective seal between the cutter seat 478 and the valve body 454. The orientation of grooves 488 and the gasket trap 440 may extrude the snb-gasket 474A into a "V~ shape" when the sub-gasket 474A is compressed, which may result in a desirable sealing arrangement. Because gaskets are generally required to attain a certain minimum level of sealin stress to produce a proper seal, the shape of the gasket trap 440 and the location of grooves 488 may be chosen to provide an optimal "calculated gasket sealing area," which can then be used to determine how much gasket material 474 should extend inward, over cylindrical bore 490 of the valve body 454 prior to completing the installation process. For example, the sealing area between the cutter seat 478 and the cross-sectional area between the gasket trap 440 and the mating surface 486 (and channel 441 and grooves 488, if present) may be calculated exactly. With the cross-sectional area calculated, the size of the gasket 474 (e.g., the inner diameter of the gasket and profile of the gasket 474, which becomes the sub-gasket 474A whe cut) needed to produce the necessary gasket 474 compression can he calculated. Accordingly, a gasket 474 can be appropriately sized to experience an adequate sealing stress between the cutter seat 478 and valve body 454, while avoiding excess material waste. j 084| When the butterfly valve 450 is folly assembled, the flat mating surface 439 may compressively engage the valve body mating surface 486, while the cutter 436 may engage a surface of the channel 441. In some embodiments, the flat mating surface 439 may also compressively engage a portion of the sub-gasket 47 A. Similarly, the cutter 436 may engage a portion of the sub-gasket 474 A. In some embodiments, the sub-gasket 47 A may be substantially contained between the cutter 436, the gasket trap 440, and the matin surface 486 of the valve body 454.

[008SJ Once the cutter seat 478 is placed into compressive engagement with the gasket 474 and the valve body 454, the seat retaining ring 470 may be assembled into place. In some embodiments, seat retaining ring 470 comprises a flat mounting surface 492 configured to engage a surface of cutter seat 478. In some embodiments, the cutter seat 478 is provided with a flange 448 that is configured to .make flat, compressive contact with the mounting surface 492 of seat retaining ring 470. In some embodiments, a seat retaining ring mounting surface 492 composes a plurality of grooves 480, which may be present to inhibit fluid flow outward from the butterfly valve 450 to the external environment The seat retaining ring 470 may also be provided with a second mounting surface 494 configured to compressive iy engage the mounting surface 482 of the valve body 454. Once the gasket 474 has been sheared into the sub-gaskets 474A, 474B, a second mounting surface 494 may be used to provide a second valve seat between the va!ve body 454 and the sealing assembly 466. The second mounting surface 494 of the seat retaining ring 470 may engage the sub-gasket 474B, as well as the mating surface 482 of the valve body 454. Using fasteners 484 (shown in FIG. 30), the seat retaining ring 470 may then be fastened to the valve body 454, in some embodiments, the fasteners 484 are chosen to maintain a near-constant compressive loading between the valve body 454, the sub-gaskets 474A, 474B, the cutter seat 478, and the seat retaining ring 470, such that adequate gasket stress is applied to the sub-gaskets 474A, 474B and a substantially leak-free seal is formed between the sealing components on multiple planes.

|0086| Referring now to FIGS. 32A-32D, an array of different butterfly valve sealing assemblies are shown, all of which may be compatible with valve components described in one or more of the embodiments discussed above. For example, FIG. 32A shows a butterfly valve assembly 500 that may be used in lower temperature applications. As can be seen in the figure provided, the standard valve body 454 and seat retaining ring 470 from the butterfly valve 450 described above may be used in this assembly, which may serve to greatly reduce the number of components required tor manufacturing across different product lines. A seat 504 is provided between valve body 454 and seat retaining ring 470, which serves both as seal between the tw components, as welt as a seal for -the valve disk 458 and the valve assembly 500. In some embodiments, the seat 504 comprises a polymeric material. In order to aid in the resiliency of the seat 504 to provide proper sealing between the seat 504 and the disk 458, an energizer 506 may be introduced within a cavity in the seat For example, the energizer 506 may comprise garter spring, which stores energy when the seat 504 is partially compressed during opening or closing of the valve 500. The energy stored by the energizer 50 may then be released to return the seat 504 to its desired shape. One or mare gaskets 502 may be used to provide a seal between the valve body 454 and the seat retaining ring 470 by being compressed between these components. In some embodiments, the one or more gaskets 502 comprise an eiastomeric material It should be appreciated, however, that non-metallic, semi-metallic, and metallic gaskets may all be used in embodiments of the present disclosure and are similarly suitable for use.

[Θ0871 In butterfly valve 600 shown i FIG. 32B, a different sea 60 is used with the standard valve body 454 and the seat retaining ring 470, which may comprise a heavy dirty polymer such a poSyurethaae, polypropylene, polytetrafiuoroethylene (PTFE), or other suitable materials. The seat 602 ma include a recess that is adapted to- receive, a backing ring 604 and wire wrapping 606. The backing ring 604 arid wire wrapping 606 provide additional compressive support to the seat 602 when the seat 602 is compressed between the valve body 454 and the seat retaining ring 470, and helps the seat 602 maintain a seal with the disk 458 when the butterfly valve 600 is closed. The gasket 502 may also be used in this assembly., and can once again be used to establish a seal between the seat retaining ring 470 and the valve body 454 when piaced under compression by these components.

[00881 PIG. 32C shows another a butterfly valve 700 that may be assembled using like components as the embodiments of FIGS, 32A and 32B. Seals are formed between the seat retaining ring 470 and the valve body 454 by compressing a seat 702 and the gasket 502 between seat the retaining ring 470 and the valve body 454. In some embodiments, the seat 702 comprises an eiastomeric material such as nitrile rubber. In other embodiments, the seat 702 may include other suitably resilient materials that allow for adequate sealing of th seat 702 between the valve body 454 and the seat retaining ring 470. A stainless steel V-ring 704 may be received within at least a portion of the seat 702 that serves to reinforce the seat 702 when it is compressed, such that adequate sealing between the disk 458 and the seat 702 can be achieved.

|0089| Referring now to FIG. 32D, yet another butterfly valve 800 is provided. Similar to the butterfly valve 450 described previously with reference to FIGS. 29-31, the butterfly valve 800 comprises a cutter seat 802, which can be used to shear a gasket 474 into a plurality of smaller gaskets to seal multiple different surfaces. The gasket 474 is once again provided to seal the surfaces between the seat retaining ring 470 and the valve body 454, as well as the surface between the cutter seat ^' 802 and the valve body 454. The cutter seat 802 may comprise racial, and may he provided with a shape similar to the shape described above with reference to the cutter seat 478. The butterfly vaive 800 may further comprise a soft seat 804, which may serve as an. additional, seat between the disk 458 and the valve body 454. In some embodiments, the soft seat 804 is comprised of reinforced tetraf!uoroethylene (RTFE) or other suitably strong and abrasion resistant to accommodate high pressure and high temperature applications. For example, some non-limiting examples of the butterfly valve 800 may incorporate a reinforced polytetraflitoroethyierie ( PTFE) soft seat. 804. The soft seat 804 may comprise a similar shape and materia! as the soft seat 82, described with reference to FIGS. 1-28.

[OO90J In traditional manufacturing methods, multiple gaskets are cut to size and then installed into the va!ve. As a vaive increases in size, a critical ratio in gasket design is reached of outer diameter versus width of the seat retaining ring seal. Large gaskets also become too delicate to manufacture and install. A traditional solution is to add a metal sleeve to increase gasket strength. These prior solutions are rendered unnecessary by the above embodiments.

[0091 J Some embodiments of the invention, allow for the insertion of sealing media into difficult sealing areas where small surface areas and large diameters make traditional gasket construction difficult or impossible. Some embodiments of the invention allow for large outside diameter gaskets with relatively small cross-sectional area sealing surfaces. The cutter acts as a shearing device on the gasket media during valve assembly.

[0092} Some embodiments of the invention allow a distinct commercial advantage by removing a manufacturing process. Some embodiments of the invention increase the sealing surface area by allowing for sealing on multiple planes from a single body gasket. Some embodiments of the invention eliminate the need for additional support material in. large, size valve gaskets. The cutter self-centers the body gasket during assembly. Some embodiments of the inventio allow gasket material to be pulled from a single "roll' ^' for assembly.

[0093} It should be appreciated that while various cutting edges have been described that are capable of producing multiple sub-gaskets from a single generic gasket, other techniques for incorporating a cutting edge into a butterfly valve assembly are similarly contemplated, and should be considered to be within the scope of the present disclosure. For example, in some embodiments of the present disclosure, a metal cutter seat and seat retaining ring may be combined into a single component that can be installed onto a gasket and valve body. In other embodiments, additive or subtractive manufacturing techniques may be utilized to incorporate the valve body, the seat retaining ring, and the metal seat ail into one single component. Such a configuration may allow for improved field assembly times. Additionally, it should be appreciated that more than two sub-gaskets may be created within a butterfly valve, and that more than one cutting edge may be utilized in the same butterfl valve. j0094] it will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and. examples, the invention is not necessarily so limited, and that numerous other ^' embodiments, examples _* uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. Further, those skilled in the art will understand thai any features of any of the embodiments disclosed herein may be utilized with any of the embodiments described herein, thereby providing varying embodiments. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. jOOfSf The seal assemblies of the present inventio are designed for in-siiu sizing where gasket material of a generic size can be used and specific dimensions required for sealing of the valve may be developed (e.g.. by cutting) during installation.

[0096j Various features and advantages of the invention are set forth in the following claims.