Rotary shear valve assembly with a polymer insert device

1. A rotary shear valve assembly comprising:

a stator device defining a substantially hard, substantially planar stator face and at least two or more stator channels in fluid communication with said stator face at corresponding stator ports;

a rotor device having a substantially hard, substantially planar rotor face defining one or more rotor channels, each rotor channel having a channel outer edge generally oriented at a channel outer diameter;

one of the stator face and the rotor face terminating at an outer circumferential edge, and the other of the rotor face and the stator face extending radially beyond the outer circumferential edge of the one stator face and the rotor face when said rotor device is rotatably mounted about a rotational axis to the stator device in a face-to-face contacting manner enabling fluid-tight, selective relative rotation between the rotor face and the stator face, at a rotor-stator interface, between two or more rotor positions; and

a polymer insert device defining an exposed contact face having an insert inner diameter greater than said channel outer diameter and less than that of said outer circumferential edge, and an insert outer diameter more than that of said outer circumferential edge, said insert device being formed and dimensioned for press-fit insertion in a receiving groove defined in the other of the rotor face and the stator face such that the outer circumferential edge of the one of the stator face and the rotor face contacts the insert exposed face during said relative rotation between said two or more rotor positions.

2. The valve assembly according to claim 1 , further including:

a compliance assembly cooperating with the rotor device in a manner orienting the substantially planar rotor face substantially parallel to and substantially flush against the substantially planar stator face of the stator device.

3. The valve assembly according to claim 1 , wherein

each rotor channel includes a channel inner diameter such that a radial transverse cross-sectional dimension from the channel inner diameter to the channel outer diameter is generally of a channel width, W c , and

wherein a minimum outer radial depth, L 1 , between the channel outer diameter and a groove inner diameter of the insert receiving groove, is at least as wide as said channel width, W c .

4. The valve assembly according to claim 1 , wherein

said insert exposed face is donut-shaped and substantially planar.

5. The valve assembly according to claim 4 , wherein

said receiving groove and said insert device cooperate to position the substantially planar insert exposed face substantially flush with said other of the substantially planar rotor face and the substantially planar stator face.

6. The valve assembly according to claim 4 , wherein

a groove inner diameter of the insert receiving groove is in the range of about 0.001 inch to about 0.002 inch greater than an insert inner diameter of the insert device, and

a groove outer diameter of the insert receiving groove is in the range of about 0.005 inch to about 0.020 inch greater than an insert outer diameter of the insert device.

7. The valve assembly according to claim 1 , wherein

said polymer insert device is composed of a high compressive strength material.

8. The valve assembly according to claim 7 , wherein

said polymer insert device is composed of one of a natural Polyaryletherketone (PAEK), a filled PAEK and a polyimide material.

9. The valve assembly according to claim 7 , wherein

said stator face and said rotor face each being composed substantially of one a metallic material and a ceramic material, said valve assembly further including:

a tribological coating disposed atop at least one of said rotor face and said stator face.

10. The valve assembly according to claim 9 , wherein

said tribological coating is a Diamond Like Carbon coating (DLC).

11. The valve assembly according to claim 10 , wherein

said tribological coating is disposed atop said stator face, and

said receiving groove is defined in said substantially planar rotor face.

12. A high pressure rotary shear valve assembly comprising:

a stator boss device defining a substantially hard, substantially planar stator face terminating at an outer circumferential edge, and further defining at least two or more stator channels in fluid communication with said stator face at corresponding stator ports;

a rotor device having a substantially hard, substantially planar rotor face defining one or more rotor channels, each rotor channel having a channel outer edge generally oriented at a channel outer diameter, said stator boss device and said rotor device are sufficiently compressed together at a high compression pressure enabling leak-tight, high pressure fluid flow between corresponding stator parts and at least one rotor channel at a face-to-face contacting rotor-stator interface therebetween in the range of at least 15 kpsi to about 25 kpsi, said rotor face extending radially beyond the outer circumferential edge of the stator face when said rotor device is rotatably mounted about a rotational axis to the stator device in a manner enabling fluid-tight, selective relative rotation between the rotor face and the stator face, at said rotor-stator interface, between two or more rotor positions;

a tribological coating disposed atop at least one of said rotor face and said stator face; and

a polymer insert device defining an exposed contact face having an insert inner diameter greater than said channel outer diameter and less than that of said outer circumferential edge, and an insert outer diameter more than that of said outer circumferential edge, said insert device being formed and dimensioned for press-fit insertion in a receiving groove defined in said rotor face such that the outer circumferential edge of said stator face contacts the insert exposed face during said relative rotation between said two or more rotor positions.

13. The valve assembly according to claim 12 , further including:

a compliance assembly cooperating with the rotor device in a manner orienting the substantially planar rotor face substantially parallel to and substantially flush against the substantially planar stator face of the stator device.

14. The valve assembly according to claim 12 , wherein

each rotor channel includes a channel inner diameter such that a radial transverse cross-sectional dimension from the channel inner diameter to the channel outer diameter is generally of a channel width, W c , and

wherein a minimum outer radial depth, L 1 , between the channel outer diameter and a groove inner diameter of the insert receiving groove, is at least as wide as said channel width, W c .

15. The valve assembly according to claim 12 , wherein

said insert exposed face is donut-shaped and substantially planar.

16. The valve assembly according to claim 15 , wherein

said receiving groove and said insert device cooperate to position the substantially planar insert exposed face substantially flush with the substantially planar rotor face.

17. The valve assembly according to claim 15 , wherein

a groove inner diameter of the insert receiving groove is in the range of about 0.001 inch to about 0.002 inch greater than that of an insert inner diameter of the insert device.

18. The valve assembly according to claim 12 , wherein said polymer insert device is composed of a high compressive strength material.

19. The valve assembly according to claim 18 , wherein

said polymer insert device is composed of one of a natural PAEK, a filled PAEK and a polyimide material.

20. The valve assembly according to claim 12 , wherein

said stator face and said rotor face each being composed substantially of one a metallic material and a ceramic material.

21. The valve assembly according to claim 20 , wherein

said tribological coating is a Diamond Like Carbon coating (DLC).

22. The valve assembly according to claim 21 , wherein

said tribological coating is disposed atop said stator face.