Additive manufacturing and generative design of hydraulic spool valves

Abstract

This application relates to additive manufacturing and generative design of a hydraulic spool valve. The spool valve includes a first inlet having a first fluid line that is substantially uniform and a second inlet having a second fluid line that is substantially uniform. A manifold chamber is in communication with the first fluid line and the second fluid line, and an outlet has a third fluid line between the first inlet and the second inlet. The third fluid line has a third inner radius that is substantially uniform along a third length of the third fluid line. A spool is disposed in the manifold chamber. A retention feature is disposed in the manifold chamber and is configured to retain the spool at one of a first position and a second position. At the first position, the spool blocks the first inlet; at the second position, the spool blocks the second inlet, but the outlet remains open. The first inlet, the second inlet, the outlet, and the manifold chamber are integrally formed as a monolithic body.

Description

Technical Field

[0001] This disclosure relates to additive manufacturing and the production design of hydraulic shuttle valves. Background Technology

[0002] A shuttle valve is a hydraulic system component with two fluid inlets and one fluid outlet, but it allows fluid to flow from only one inlet to the outlet at a time. In other words, a shuttle valve allows fluid to flow from a first inlet to the outlet, or from a second inlet to the outlet, but not both simultaneously. The shuttle valve switches the fluid inflow between the first and second inlets based on the relative fluid pressures in the two inlets. Summary of the Invention

[0003] One or more embodiments provide a shuttle valve. The shuttle valve includes a first inlet having a first connection region communicating with a first fluid line. The first fluid line has a first inner radius that is substantially uniform along a first length of the first inlet. The shuttle valve also includes a second inlet having a second connection region communicating with a second fluid line. The second fluid line has a second inner radius that is substantially uniform along a second length of the second inlet. The shuttle valve also includes a manifold chamber communicating with the first fluid line and opposite to the first connection region, and communicating with the second fluid line and opposite to the second connection region. The shuttle valve also includes an outlet having a third connection region communicating with a third fluid line. The third fluid line communicates with the manifold chamber between the first and second inlets. The third fluid line has a third inner radius that is substantially uniform along a third length of the third fluid line. The shuttle valve also includes a valve spool disposed in the manifold chamber. The shuttle valve also includes a retaining feature disposed in the manifold chamber and configured to retain the valve spool in one of a first position and a second position. In the first position, the first end of the valve core blocks the first inlet. In the second position, the second end of the valve core blocks the second inlet. In either the first or second position, the outlet remains open. The first inlet, second inlet, outlet, and manifold chamber are integrally formed into a single unit.

[0004] One or more embodiments also provide a manufacturing method. The method includes forming an integrally formed monolithic body using an additive manufacturing process. The integrally formed monolithic body further includes a first inlet having a first connection region communicating with a first fluid line. The first fluid line has a first inner radius substantially consistent along a first length of the first inlet. The integrally formed monolithic body further includes a second inlet having a second connection region communicating with a second fluid line. The second fluid line has a second inner radius substantially consistent along a second length of the second inlet. The integrally formed monolithic body further includes a manifold chamber communicating with the first fluid line and opposite to the first connection region, and communicating with the second fluid line and opposite to the second connection region. The integrally formed monolithic body further includes an outlet having a third connection region communicating with a third fluid line. The third fluid line communicates with the manifold chamber between the first and second inlets. The third fluid line has a third inner radius substantially consistent along a third length of the third fluid line. The method further includes inserting a valve core into the manifold chamber. The method further includes inserting a retaining feature into the manifold chamber, the retaining feature being configured to hold the valve spool in one of a first position and a second position. In the first position, a first end of the valve spool blocks a first inlet. In the second position, a second end of the valve spool blocks a second inlet. In either the first or second position, the outlet remains open.

[0005] One or more embodiments also provide an aircraft. The aircraft includes a fuselage and a landing gear system connected to the fuselage. The aircraft may include a hydraulic braking system connected to the landing gear system. The hydraulic braking system may include a shuttle valve. The shuttle valve includes a first inlet having a first connection region communicating with a first fluid line. The first fluid line has a first inner radius that is substantially consistent along a first length of the first inlet. The shuttle valve also includes a second inlet having a second connection region communicating with a second fluid line. The second fluid line has a second inner radius that is substantially consistent along a second length of the second inlet. The shuttle valve also includes a manifold chamber communicating with the first fluid line and opposite to the first connection region, and communicating with the second fluid line and opposite to the second connection region. The shuttle valve also includes an outlet having a third connection region communicating with a third fluid line. The third fluid line communicates with the manifold chamber between the first and second inlets. The third fluid line has a third inner radius that is substantially consistent along a third length of the third fluid line. The shuttle valve also includes a valve core disposed in the manifold chamber. The shuttle valve also includes a retaining feature disposed in the manifold chamber and configured to retain the valve core in one of a first position and a second position. In the first position, a first end of the valve core blocks a first inlet. In the second position, a second end of the valve core blocks a second inlet. In either the first or second position, the outlet remains open. The first inlet, second inlet, outlet, and manifold chamber are integrally formed into a single unit.

[0006] Other aspects of the invention will become apparent from the following description. Attached Figure Description

[0007] Figure 1 An aircraft is shown in which a shuttle valve of one or more embodiments of the present invention may be placed.

[0008] Figure 2 The symbol for a shuttle valve according to one or more embodiments of the present invention is shown.

[0009] Figure 3 A block diagram of a shuttle valve according to one or more embodiments of the present invention is shown.

[0010] Figure 4 A manufacturing method according to one or more embodiments of the present invention is shown.

[0011] Figure 5 A shuttle valve of the prior art is shown.

[0012] Figure 6 A shuttle valve manufactured using additive manufacturing technology according to one or more embodiments of the present invention is shown.

[0013] Figure 7 An adapter for a shuttle valve, manufactured using additive manufacturing technology according to one or more embodiments of the present invention, is shown.

[0014] Figure 8 A method for manufacturing and maintaining the product according to one or more embodiments of the present invention is shown.

[0015] Figure 9 An aircraft according to one or more embodiments of the present invention is shown. Detailed Implementation

[0016] Specific embodiments of the invention will now be described in detail with reference to the accompanying drawings. For consistency, the same elements in the figures are indicated by the same reference numerals.

[0017] In the following detailed description of embodiments of the invention, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention can be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

[0018] Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as adjectives for elements (i.e., any noun in the application). Unless explicitly disclosed, the use of ordinal numbers does not imply or create any particular order of elements, nor does it limit any element to a single element, for example, by using the terms “before,” “after,” “single,” and other such terms. Rather, the use of ordinal numbers is for distinguishing elements. As an example, a first element is distinct from a second element, and a first element may contain more than one element and be in the order of elements after (or before) the second element.

[0019] The term "substantially," when used in relation to measurable physical properties, refers to engineering tolerances anticipated or determined by an engineer or manufacturing technician skilled in the art. The precise quantification of engineering tolerances depends on the product being manufactured and the technical performance being measured. For a non-limiting example, two angles may be "substantially congruent" if their values ​​are within 10 percent of each other. However, if an engineer determines that the engineering tolerances for a particular product should be more stringent, "substantially congruent" could be two angles having values ​​within 1 percent of each other. Similarly, in other embodiments, engineering tolerances may be relaxed such that "substantially congruent" angles have values ​​within 20 percent of each other. In any case, a person skilled in the art can assess what acceptable engineering tolerances are for a particular product and therefore can assess how to determine the variation in measurement anticipated by the term "substantially."

[0020] As used herein, the term "connected to" is intended to have at least two meanings. In the first meaning, unless otherwise stated, "connected to" means that part A is separated from part B at least at some point, but is subsequently attached to part B in an arrangement that is fixed or removable. In the second meaning, unless otherwise stated, "connected to" means that part A can be integrally formed with part B. Thus, for example, suppose the bottom of a pan is "connected to" the walls of the pan. The term "connected to" can be interpreted as the bottom and walls being separate parts that are snapped together, welded, or otherwise fixedly or removably attached to each other. Alternatively, the term "connected to" can also be interpreted as the bottom and walls being continuously joined together as a monolithic body formed by, for example, a molding process. In other words, the bottom and walls "connected" to each other can be separate parts placed together and connected, or they can be single pieces of material bent at an angle such that the bottom panel and wall panel are identifiable parts of a single piece of material.

[0021] Typically, embodiments of the present invention relate to a shuttle valve with a monolithic body that eliminates many seals and other components required in prior art shuttle valves. One or more embodiments of the shuttle valve integrate end fittings with the housing manifold, which eliminates leakage paths and reduces the number of parts from seven to one compared to prior art shuttle valves. Instead, additive manufacturing (sometimes referred to as “3D printing”) is used to fabricate the integrated manifold housing. Generative design methods are used to modify the entire housing manifold design and eliminate excess material. Adapters are eliminated to facilitate integrated adapters at the inlet and outlet, further reducing the number of parts and leakage paths.

[0022] Furthermore, the integrated design reduces assembly time, as well as overall manufacturing effort and cost. Eliminating parts and leakage paths increases the shuttle valve's lifespan and performance. Material waste is reduced, and less material is used in manufacturing compared to machining techniques, saving money.

[0023] Furthermore, additive manufacturing utilizes safer machinery compared to traditional subtractive milling and lathe operations, which require trained professionals to ensure high-quality and safe operation. The additive manufacturing process also reduces weight, particularly through generative design techniques and seal elimination. Therefore, shuttle valves in one or more embodiments offer a simplified assembly process and reduced assembly time, while providing an improved design with better performance compared to existing shuttle valves.

[0024] Figure 1An aircraft 100 is illustrated, in which one or more embodiments of the invention may house shuttle valves of one or more embodiments. The aircraft 100 includes a fuselage 102, a first wing 104, a second wing 106, and a tail 108. The aircraft 100 may also include a propulsion system, such as a first engine 110 and a second engine 112. The aircraft may also include one or more hydraulic systems, such as a first hydraulic braking system 114 and a second hydraulic braking system 116. Each hydraulic braking system may include one or more shuttle valves. For example, the first hydraulic braking system 114 includes a first shuttle valve 118 and a second shuttle valve 120, and the second hydraulic braking system 116 includes a third shuttle valve 122 and a fourth shuttle valve 124. In addition to the components described above, the aircraft 100 may include additional components. Note that shuttle valves can be used in other hydraulic systems of the aircraft. It should also be noted that shuttle valves (including those described herein) are commonly used in many different hydraulic systems in a variety of products other than aircraft.

[0025] Figure 2 The symbol for a shuttle valve according to one or more embodiments of the present invention is shown. The shuttle valve 200 may be... Figure 1 The shuttle valve 200 comprises any one of the following: a first shuttle valve 118, a second shuttle valve 120, a third shuttle valve 122, and a fourth shuttle valve 124. The shuttle valve 200 includes a first inlet 202, a second inlet 204, and an outlet 206. Fluid flows from the first inlet 202 through the manifold chamber 210 and to the outlet 206; or, fluid flows from the second inlet 204 through the manifold chamber 210 and to the outlet 206. However, fluid does not flow from both the first inlet 202 and the second inlet 204 simultaneously. The shuttle assembly 208 within the shuttle valve 200 blocks either the first inlet 202 or the second inlet 204 based on the pressure in both inlets.

[0026] When the pressure in one inlet exceeds a threshold pressure relative to the other inlet, the shuttle assembly 208 is forced to reach the opposite inlet. Figure 2 In the example, the pressure in the first inlet 202 is higher than the threshold pressure relative to the second inlet 204. Therefore, the shuttle assembly 208 blocks the second inlet 204, allowing fluid to flow from the first inlet 202 to the outlet 206.

[0027] Figure 3 A block diagram of a shuttle valve according to one or more embodiments of the present invention is shown. Figure 3 The shuttle valve 300 shown can be used Figure 1 The aircraft 100 shown can be used for Figure 2 The shuttle valve 200 shown.

[0028] The shuttle valve 300 includes a first inlet 302 having a first connection region 304 communicating with a first fluid line 306. As used herein, a "connection region" refers to a portion of the inlet or outlet that is constructed, sized, and designed to connect with other components in the hydraulic system. For example, a "connection region" may be constructed as part of a monolithic body with predetermined radii, fittings, pawls, threads, etc., intentionally designed to connect the fluid line of the shuttle valve 300 to another fluid line in the hydraulic system, or to other components in the hydraulic system. Thus, the term "connection region" has a defined structure, although the defined structure is for connection, the defined structure can be implemented in various different ways.

[0029] Additionally, as used herein, the term "fluid pipeline" refers to a hollow tube of any cross-sectional shape through which fluid flows. Figure 3 In the example, the first fluid line 306 has a first inner radius that is substantially consistent along a first length of the first inlet 302. However, in other embodiments, the cross-section of the first inlet 302 may vary, or it may include other sub-components.

[0030] The shuttle valve 300 also includes a second inlet 308 having a second connection region 310 communicating with a second fluid line 312. The second fluid line 312 has a second inner radius that is substantially consistent along the second length of the second inlet. However, again, the second connection region 310 and the second fluid line 312 can vary, as defined and described above with respect to the first connection region 304 and the first fluid line 306.

[0031] The shuttle valve 300 also includes a manifold chamber 314 that communicates with a first fluid line 306 and is opposite to a first connection region 304, and communicates with a second fluid line 312 and is opposite to a second connection region 310. In other words, the manifold chamber 314 is located between the first inlet 302 and the second inlet 308 relative to the direction of fluid flow from the first inlet 302 or the second inlet 308.

[0032] The shuttle valve 300 also includes an outlet 316 having a third connection region 318 communicating with a third fluid line 320. The third fluid line 320 communicates with a manifold chamber 314 between a first inlet 302 and a second inlet 308. The third fluid line 320 has a third inner radius that is substantially consistent along a third length of the third fluid line 320.

[0033] The shuttle valve 300 also includes a valve core 324 disposed in the manifold chamber 314. The valve core 324 is an object that can slide longitudinally between the first inlet 302 and the second inlet 308 within the manifold chamber 314. As shown, the valve core 324 can be a cylindrical object, but can have different cross-sectional shapes.

[0034] The shuttle valve 300 also includes a retaining feature 326 disposed in the manifold chamber 314. The retaining feature 326 is configured to retain the valve core 324 in either a first position 328 or a second position 330 within the manifold chamber 314. The retaining feature 326 may be a spring, deformable object, deformable ring, solid object, or ring, or other possible object, pressed against a deformable feature or pressed into or into a groove in a sleeve 332 disposed in the manifold chamber 314. In any case, the retaining feature 326 pushes the valve core 324 to retain it in the appropriate position within the manifold chamber 314 until the fluid pressure difference between the first inlet 302 and the second inlet 308 exceeds a threshold fluid pressure.

[0035] In the first position 328, the first end of the valve core 324 blocks the first inlet 302. In the second position 330, the second end of the valve core 324 blocks the second inlet 308. In either the first position 328 or the second position 330, the outlet 316 remains open.

[0036] The valve core 324 shifts back and forth between a first position 328 and a second position 330 based on the fluid pressure difference between the first inlet 302 and the second inlet 308. When the fluid pressure difference between the fluid pressure at the first inlet 302 and the fluid pressure at the second inlet 308 exceeds a threshold fluid pressure, the force applied by the holding feature 326 is overcome. Therefore, the valve core 324 shifts from the first position 328 to the second position 330. Conversely, when the fluid pressure difference between the fluid pressure at the second inlet 308 and the fluid pressure at the first inlet 302 exceeds the threshold fluid pressure, the force applied by the holding feature 326 is overcome again. Therefore, the valve core 324 shifts from the second position 330 back to the first position 328.

[0037] In this way, fluid can flow from either the first inlet 302 or the second inlet 308, but not simultaneously during normal operation of the shuttle valve 300. Note that for a brief period of time, the valve core 324 may be in an intermediate position between the first position 328 and the second position 330. In the intermediate position, depending on the design of the valve core 324 and / or the sleeve 332 surrounding the valve core 324, fluid can flow from both inlets simultaneously for a brief period. However, the time it takes for the valve core 324 to shift from the first position 328 to the second position 330 is rapid, typically less than one second. Therefore, in practice, the retaining feature 326 will prevent the valve core 324 from taking the intermediate position for any longer period of time. Thus, in practice, for operational purposes, the valve core 324 will be in either the first position 328 or the second position 330, but not in between.

[0038] The first inlet 302, the second inlet 308, the outlet 316, and the manifold chamber 314 are integrally formed as a single unit. As used herein, the term "monomeric" means integrally formed as a single, unified unit, as opposed to a device initially formed from separate components that are then joined together and connected via techniques such as welding, gluing, bolting, threading, tape bonding, assembly, interlocking, etc. Thus, although the shuttle valve 300 may have a complex shape with regions having given names (e.g., first inlet 302, first connection area 304, first fluid line 306, second inlet 308, second connection area 310, second fluid line 312, manifold chamber 314, outlet 316, third connection area 318, third fluid line 320, and filter 322), all these areas are single, unified units without seams, joints, etc. However, note that when the shuttle valve 300 moves within the manifold chamber 314, the valve core 324 and the retaining feature 326 separate from the single-piece body of the shuttle valve 300.

[0039] The shuttle valve 300 described above may have additional variations or components added to the monolithic body. For example, the first cross-section of the first inlet 302, the second cross-section of the second inlet 308, and the third cross-section of the outlet 316 may be substantially identical. All three cross-sections need not be equal; however, the individual cross-sections may be identical, with minimal variation in cross-sectional area. In this case, the outlet 316 may extend radially from the manifold chamber 314 a first distance. The third fluid line 320 then has a bend at the first distance before terminating at the third connection region 318. Furthermore, the third fluid line 320 may be bent such that the end region of the third fluid line 320 is substantially parallel to the second fluid line 312 of the second inlet 308.

[0040] In the above variation, the notch region 334 may be located between the outlet 316 and the second inlet 308. Note that the term "notch" in the notch region 334 does not imply that the shuttle valve 300 has been milled or cut. Rather, the term "notch" simply indicates that the monolithic body of the shuttle valve 300 has been formed such that "empty space" exists in the notch region 334. For example, using additive manufacturing, a 3D printer can be arranged to avoid depositing material in the notch region 334, thereby forming a shuttle valve 300 with the notch region 334.

[0041] Due to strength engineering specifications, in known shuttle valves, for example... Figure 5 The cut area 334 of the prior art shuttle valve 500 shown may not be possible. Furthermore, even if it could be... Figure 5 The existing shuttle valve 500 has a cutout area 334. Constructing the single body of the shuttle valve 300 with a cutout area 334 can also save materials, manufacturing time and money, and reduce the weight of the shuttle valve 300, thereby improving the efficiency of manufacturing the shuttle valve 300 without sacrificing any strength engineering specifications.

[0042] Other variations are also possible. For example, filter 322 may be integrally formed with the outlet in the third fluid line 320, possibly after the bend and possibly before the bend. Filter 322 is also part of the monolithic body of shuttle valve 300 and is therefore formed as a solid region through which one or more orifices pass to allow fluid flow through the third fluid line 320 at outlet 316.

[0043] The shuttle valve 300 may also have other variations. For example, one or more mounting tabs, such as mounting tab A 336 and mounting tab B 338, may be integrally formed on the outer side of the manifold chamber 314. The mounting tabs can facilitate the installation of the shuttle valve 300 to other components in the hydraulic system or to a support outside the hydraulic system.

[0044] The shuttle valve 300 may further include a first valve core retainer 340 disposed at a first intersection between the first fluid line 306 and the manifold chamber 314. The first valve core retainer 340 effectively holds the valve core 324 in a first position 328 until a fluid pressure differential forces the valve core 324 to move, as described above. The first valve core retainer 340 includes a fourth fluid line 342 communicating with the first fluid line 306, and the fourth fluid line has a fourth inner radius substantially equal to the first inner radius of the first fluid line 306.

[0045] Similarly, the shuttle valve 300 may also include a second valve core retainer 344 disposed at a second intersection between the second fluid line 312 and the manifold chamber 314. The second valve core retainer 344 effectively holds the valve core 324 in the second position 330 until a fluid pressure differential forces the valve core 324 to move, as described above. The second valve core retainer 344 includes a fifth fluid line 346 communicating with the second fluid line 312, and the fifth fluid line has a fifth inner radius substantially equal to the second inner radius of the second fluid line 312.

[0046] The shuttle valve 300 may also include a sleeve 332 surrounding the valve core 324. Thus, the sleeve 332 is disposed within the manifold chamber 314. The valve core 324 slides longitudinally within the sleeve 332 between a first position 328 and a second position 330. A retaining feature 326 may be disposed between the sleeve 332 and the valve core 324. In this case, the manifold chamber 314 is completely closed except for the first inlet 302, the second inlet 308, and the outlet 316, with the combination of the valve core 324 and the sleeve 332 disposed within the manifold chamber 314. In yet another embodiment, the sleeve 332 may be part of a monolithic body of the shuttle valve 300, but the valve core 324 is added later by placing it inside the sleeve 332.

[0047] Other variations are also possible. Therefore, one or more implementations are not necessarily limited to the examples given above.

[0048] Figure 4 A manufacturing method according to one or more embodiments of the present invention is shown. Figure 4 The method can be used to manufacture Figure 3 The shuttle valve 300, and / or relative to Figure 6 and Figure 7 Various implementation methods are shown.

[0049] In step 400, an integrally formed monolithic body is formed using an additive manufacturing process. This integrally formed monolithic body includes: a first inlet having a first connection region communicating with a first fluid line, wherein the first fluid line includes a first inner radius substantially consistent along a first length of the first inlet; a second inlet having a second connection region communicating with a second fluid line, wherein the second fluid line includes a second inner radius substantially consistent along a second length of the second inlet; a manifold chamber communicating with the first fluid line and opposite to the first connection region, and communicating with the second fluid line and opposite to the second connection region; and an outlet having a third connection region communicating with a third fluid line, wherein the third fluid line communicates with the manifold chamber between the first and second inlets, and wherein the third fluid line includes a third inner radius substantially consistent along a third length of the third fluid line. Step 400 can be performed using an additive manufacturing process based on a generative design model provided as input to an additive manufacturing machine. For example, a design model can be provided to a 3D printer, and the monolithic body can be "printed" in a printing chamber.

[0050] At step 402, the sleeve-valve assembly is inserted into the manifold chamber. The sleeve and valve core may be formed separately before insertion into the manifold chamber. Alternatively, the valve core may be inserted into the sleeve that has already been formed together with the manifold chamber. Alternatively, the valve core is inserted into the manifold chamber and then into the sleeve.

[0051] At step 404, the retaining feature is inserted into the manifold chamber, and the retaining feature is configured to hold the valve spool in one of a first position and a second position. In the first position, the first end of the valve spool blocks the first inlet. In the second position, the second end of the valve spool blocks the second inlet. The outlet remains open in either the first or second position. In one embodiment, Figure 4 The method can be terminated after this.

[0052] Figure 4 The methods can vary, including, for example Figure 4 The optional steps are shown in the dashed box. For example, at step 406, possibly instead of step 404, a first valve retainer may be inserted at a first intersection between the first fluid line and the manifold chamber. The first valve retainer includes a fourth fluid line communicating with the first fluid line and having a fourth inner radius substantially equal to the first inner radius. Similarly, at step 408, a second valve retainer may be inserted at a second intersection between the second fluid line and the manifold chamber. The second valve retainer includes a fifth fluid line communicating with the second fluid line and having a fifth inner radius substantially equal to the second inner radius.

[0053] As described above, at step 410, the sleeve can be inserted into the manifold chamber. The valve spool can be inserted into the sleeve before or after insertion into the manifold chamber. The valve spool slides longitudinally within the sleeve between a first position and a second position.

[0054] In one embodiment, the integrally formed monolithic body is configured such that the first cross-section of the first inlet, the second cross-section of the second inlet, and the third cross-section of the outlet are substantially equal. Additionally, the integrally formed monolithic body may be configured such that the outlet extends radially from the manifold chamber by a first distance, and the third fluid line has a bend at the first distance before terminating at the third connection region.

[0055] In this configuration, the integrally formed monolithic body can be configured such that the third fluid line is bent such that the end region of the third fluid line is substantially parallel to the second fluid line at the second inlet. In this configuration, at step 412, the method may further include forming the integrally formed monolithic body such that a cut-out region is positioned between the outlet and the second inlet.

[0056] Optionally, at step 414, the method may further include forming an integrally formed monolithic body such that the filter and the outlet in the third fluid line are integrally formed after the bend. Other features may also be integrally formed with the monolithic body.

[0057] Although the steps in this flowchart are presented and described sequentially, those skilled in the art will understand that some or all of the steps may be performed in a different order, may be combined or omitted, and may be performed in parallel. Therefore, one or more implementations are not necessarily limited to the examples provided above.

[0058] Figure 5 A prior art shuttle valve is shown. The shuttle valve 500 includes a first inlet 502 and a second inlet 504 that allow fluid to flow into a manifold chamber 506. An outlet 508 allows fluid to flow out of the manifold chamber 506.

[0059] The sleeve 510 in the manifold chamber 506 holds the valve spool 512. The valve spool can slide back and forth between the first inlet 502 and the second inlet 504, depending on the changing fluid pressure in the two inlets. In the first position, as... Figure 5 As shown, valve core 512 blocks the first inlet 502. In Figure 5 In the second position (not shown), valve core 512 blocks the second inlet 502.

[0060] As the C-spring 514 receives and pushes downward the retaining feature 516, which contacts the valve spool 512, the valve spool 512 is pushed to remain in either position. The retaining feature 516 is disposed in a groove in the sleeve 510. When the fluid pressure from the first inlet 502 becomes higher than the threshold pressure difference relative to the fluid pressure from the second inlet 504, the retaining feature 516 is pushed against the side of the insert in which the valve spool 512 is positioned. The retaining feature 516 may deform (be squeezed) or otherwise be forced to roll out of the insert. As a result, the valve spool 512 of the shuttle valve moves to a new position where another groove 518 in the valve spool 512 receives the retaining feature 516. Again, the C-spring 514 retains the retaining feature 516, but now in a second position.

[0061] However, Figure 5 The existing shuttle valve 500 shown has several problems. The C-spring 514 wears and may allow the retaining feature 516 to detach and fall into the outlet 508. Therefore, a filter disc 520 is present to prevent the loose retaining feature 516 from moving into other parts of the hydraulic system. Meanwhile, the shuttle valve 500 can operate outside of engineering tolerances and may therefore require maintenance and / or replacement, which can be an expensive procedure.

[0062] Another problem with the existing shuttle valve 500 is the need for several seals, such as seal 522, to ensure no fluid leakage. Each of these seals may require costly maintenance procedures.

[0063] Figure 6 A shuttle valve manufactured using additive manufacturing technology according to one or more embodiments of the present invention is shown. Figure 6 The shuttle valve 600 shown is Figure 3 A variation of the shuttle valve 300 shown, and for Figure 5 The existing shuttle valve 500 shown has undergone substantial improvements.

[0064] The shuttle valve 600 includes a housing 602 that forms a monolithic body encompassing all areas of the shuttle valve 600 except for the valve core 614. In other words, in addition to what has been mentioned, refer to... Figure 6 All components described are part of the monolithic housing 602. The various parts described below are considered to be areas integrated with housing 602.

[0065] Therefore, the housing 602 of the shuttle valve 600 includes a first inlet 604 and a second inlet 606 that allow fluid to flow into the manifold chamber 608. The outlet 610 allows fluid to flow out of the manifold chamber 608.

[0066] Sleeve 612 is disposed within manifold chamber 608. Valve spool 614 is slidably disposed within sleeve 612 and is therefore not integrally formed with housing 602. Housing 602 may also include a first retainer 616 and a second retainer 618. When housing 602 and valve spool 614 are formed of metal, the first retainer 616 and the second retainer 618 allow metal-to-metal contact between valve spool 614 and the retainers.

[0067] The shuttle valve 600 may also include a filter 626. The size and dimensions of the filter 626 may be designed to remove particulate or foreign matter debris (FOD) from the working fluid entering the outlet 610.

[0068] Other optional features may also be present, such as a first O-ring 628 and a second O-ring 630. The O-rings can serve as backup seals for the first retainer 616 and the second retainer 618, respectively. In another embodiment, mounting tabs may be integrally formed with the housing 602, such as a first mounting tab 632, a second mounting tab 634, a third mounting tab 636, and a fourth mounting tab 638. More or fewer mounting tabs may be present. Other optional features may also be present. Therefore, one or more embodiments are not necessarily limited to... Figure 6 The example shown.

[0069] Figure 6 The shuttle valve 600 shown is relative to Figure 5 The prior art shuttle valve 500 shown has many improved features. For example, because the shuttle valve 600 is formed into the monolithic housing 602 using additive manufacturing, it does not require... Figure 5 The prior art shuttle valve 500 shown requires a plug to be drilled into the valve core 614 through the housing, opposite to the outlet 610. Figure 5 The existing shuttle valve 500 requires a plug that facilitates drilling a 90-degree flow path at the outlet 610, but additive manufacturing can create a 90-degree flow path without requiring a plug. Figure 5 The plug required in the prior art shuttle valve 500 shown is not shown. Furthermore, without the plug, the valve core 614 has a smooth internal geometry, thereby improving the fluid flow efficiency within the shuttle valve 600.

[0070] Furthermore, the shuttle valve 600 is lighter than the prior art shuttle valve 500. The shuttle valve 600 has fewer parts and can be constructed with a cut-out area 640 without cutting or wasting material. In hydraulic systems, such as those in aircraft, lighter components are desirable, where weight is a persistent issue directly related to fuel consumption and therefore to the operating costs of the aircraft.

[0071] In addition, the shuttle valve 600 reduces Figure 5The total number of components in the prior art shuttle valve 500 is shown. More than 10 or more components in the prior art shuttle valve 500 can be reduced to a single housing 602. As a result, the speed, efficiency, and cost-effectiveness of manufacturing the shuttle valve 600 are improved. Furthermore, the shuttle valve 600 will have improved durability and operational efficiency, further reducing maintenance costs. In addition, since no drilling or machining operations are required, no special operational skills are needed to manufacture the shuttle valve 600. Material waste is significantly reduced or eliminated, and the assembly process is simplified and becomes faster. Therefore, one or more embodiments represent a substantial improvement over known technology.

[0072] Figure 7 An adapter for a shuttle valve, manufactured using additive manufacturing technology according to one or more embodiments of the present invention, is shown. Figure 7 The shuttle valve 700 shown is Figure 6 The shuttle valve 600 shown and Figure 3 The shuttle valve 300 shown is a variant.

[0073] Figure 7 This illustrates that the shuttle valve 700 need not be a completely single-piece unit. For engineering reasons, it may be desirable to use additive manufacturing to form two or more parts of the shuttle valve 700, and then join these parts together. Thus, for example, Figure 6 The second inlet 606 shown can be replaced by an adapter 702, which is then fitted into the manifold chamber 704. The retaining feature 706 of the adapter 702 can then be positioned in a groove 708 provided in the wall of the manifold chamber 704. Thereafter, once the valve core (not shown) is placed inside the manifold chamber 704, the shuttle valve 700 can be operated as described above.

[0074] Although Figure 6 and Figure 7 The construction of the components is shown, but other constructions may be used without departing from the scope of the invention. For example, various components can be combined to create a single component, such as... Figure 6 As shown. As another example, a function performed by a single component can be performed by two or more components, such as... Figure 7 As shown.

[0075] Figure 8 A flowchart is shown of a method for manufacturing and maintaining at a second location according to one or more embodiments of the present invention. Figure 9 A block diagram of an aircraft in a second position according to one or more embodiments of the present invention is shown.

[0076] Turning Figure 8 During pre-production, the exemplary aircraft manufacturing and maintenance method 800 may include Figure 9The specifications and design of the aircraft 900 (802) and the material procurement for the aircraft 900 (804) are discussed. During production, [further details are needed]. Figure 9 The manufacturing of components and sub-assemblies of the aircraft 900 is 806, and system integration is 808. Afterwards, Figure 9 The 900 aircraft can be certified and delivered (810) for service (812). When used by customers, Figure 9 The aircraft 900 is scheduled for routine maintenance and repair 814, which may include modifications, reconstruction, overhauls, and other maintenance or repairs.

[0077] Each process of the Aircraft Manufacturing and Maintenance Method 800 can be performed or implemented by a systems integrator, a third party, and / or an operator. In these examples, the operator can be the customer. For the purposes of this specification, the systems integrator can be, but is not limited to, any number of aircraft manufacturers and main system subcontractors; the third party can be, but is not limited to, any number of suppliers, subcontractors, and suppliers; and the operator can be an airline, leasing company, maintenance organization, etc.

[0078] Now for reference Figure 9 The illustration depicts an aircraft 900 in which an advantageous implementation can be achieved. In this example, the aircraft 900 is composed of... Figure 8 The aircraft is manufactured and repaired using method 800. The aircraft 900 may include a fuselage 902 having systems 904 and an interior 906. Examples of systems 904 include one or more of a propulsion system 908, an electrical system 910, a hydraulic system 912, and an environmental system 914. Any number of other systems may be included.

[0079] Although an aerospace example has been shown, different advantageous implementations can be applied to other industries, such as the automotive industry. Therefore, for example, in one or more embodiments, the aircraft 900 can be replaced by a car or other means of transportation or object.

[0080] The equipment and methods implemented here can Figure 8 Used during any one or more stages of the aircraft manufacturing and maintenance methods 800. For example, in Figure 8 The parts or subassemblies manufactured in part 806 can be produced in a manner similar to that in Figure 8 The aircraft 900 was produced or manufactured in the manner of producing parts or sub-assemblies when it entered service.

[0081] Moreover, during the production phase, for example Figure 8During the manufacturing of components and sub-assemblies 806 and system integration 808, one or more equipment implementations, method implementations, or combinations thereof can be utilized, for example, to significantly accelerate the assembly of the aircraft 900 or reduce its cost. Similarly, in Figure 8 In the process, when the aircraft 900 is put into service 812 or during maintenance and repair 814, one or more equipment implementations, method implementations or combinations thereof may be used.

[0082] For example, during component and subassembly manufacturing 806, one or more advantageous implementations can be applied to correct inconsistencies that may be found in the composite structure. As yet another example, one or more advantageous implementations can be implemented during maintenance and repair 814 to remove or mitigate any inconsistencies that may be identified. Therefore, regarding Figures 1 to 9 One or more of the described embodiments may be implemented during component and sub-assembly manufacturing 806 and / or during maintenance and repair 814 to remove or mitigate identifiable inconsistencies.

[0083] Clause 1. According to one aspect of this disclosure, a shuttle valve is provided, the shuttle valve comprising: A first inlet, the first inlet having a first connection region communicating with a first fluid line, wherein the first fluid line includes a first inner radius substantially consistent along a first length of the first inlet; The second inlet has a second connection region communicating with a second fluid line, wherein the second fluid line includes a second inner radius that is substantially consistent along a second length of the second inlet; A manifold chamber, which is in communication with the first fluid line and opposite to the first connection area, and in communication with the second fluid line and opposite to the second connection area; An outlet having a third connection region communicating with a third fluid line, wherein the third fluid line communicates with the manifold chamber located between the first inlet and the second inlet, and wherein the third fluid line includes a third inner radius substantially consistent along a third length of the third fluid line; Valve core, the valve core being disposed in the manifold chamber; and A retaining feature is disposed in the manifold chamber and configured to retain the valve core in one of a first position and a second position, wherein, in the first position, a first end of the valve core blocks the first inlet, wherein, in the second position, a second end of the valve core blocks the second inlet, and wherein, in either the first position or the second position, the outlet remains open; The first inlet, the second inlet, the outlet, and the manifold chamber are integrated into a single unit.

[0084] Clause 2. The shuttle valve described in Clause 1, wherein the first cross-section of the first inlet, the second cross-section of the second inlet, and the third cross-section of the outlet are substantially the same.

[0085] Clause 3. The shuttle valve described in Clause 2, wherein: The outlet extends radially from the manifold chamber by a first distance, and The third fluid line has a bend at the first distance before terminating at the third connection region.

[0086] Clause 4. The shuttle valve described in Clause 3, wherein the third fluid line is bent such that the end region of the third fluid line is substantially parallel to the second fluid line of the second inlet.

[0087] Clause 5. The shuttle valve described in Clause 4, wherein the shuttle valve further comprises: A cut area is provided between the outlet and the second inlet.

[0088] Clause 6. The shuttle valve described in Clause 5, wherein the shuttle valve further comprises: A filter is integrally formed with the outlet in the third fluid line and after the bend.

[0089] Clause 7. The shuttle valve described in Clause 6, wherein the shuttle valve further comprises: Multiple mounting tabs are integrally formed on the outer side of the manifold chamber.

[0090] Clause 8. The shuttle valve described in Clause 1, wherein the shuttle valve further comprises: A first valve core retainer is disposed at a first intersection between the first fluid line and the manifold chamber. The first valve core retainer includes a fourth fluid line communicating with the first fluid line and having a fourth inner radius substantially the same as the first inner radius. A second valve core retainer is disposed at a second intersection between the second fluid line and the manifold chamber. The second valve core retainer includes a fifth fluid line that communicates with the second fluid line and has a fifth inner radius that is substantially the same as the second inner radius.

[0091] Clause 9. The shuttle valve described in Clause 1, wherein the shuttle valve further comprises: A sleeve is disposed within the manifold chamber, wherein the valve core slides longitudinally within the sleeve between the first position and the second position.

[0092] Clause 10. The shuttle valve of Clause 9, wherein the retaining feature is disposed between the sleeve and the valve core.

[0093] Clause 11. The shuttle valve of Clause 1, wherein the manifold chamber is completely closed except for the first inlet, the second inlet and the outlet.

[0094] Clause 12. According to another aspect of this disclosure, a manufacturing method is provided, the method comprising: A monolithic body is formed using additive manufacturing processes, wherein the monolithic body comprises: A first inlet, the first inlet having a first connection region communicating with a first fluid line, wherein the first fluid line includes a first inner radius substantially consistent along a first length of the first inlet; The second inlet has a second connection region communicating with a second fluid line, wherein the second fluid line includes a second inner radius that is substantially consistent along a second length of the second inlet; A manifold chamber, which is in communication with the first fluid line and opposite to the first connection area, and in communication with the second fluid line and opposite to the second connection area; An outlet having a third connection region communicating with a third fluid line, wherein the third fluid line communicates with the manifold chamber located between the first inlet and the second inlet, and wherein the third fluid line includes a third inner radius substantially consistent along a third length of the third fluid line; and Insert the sleeve-valve core assembly into the manifold chamber; and A retaining feature is inserted into the manifold chamber, the retaining feature being configured to retain the valve core in one of a first position and a second position, wherein, in the first position, a first end of the valve core blocks the first inlet, wherein, in the second position, a second end of the valve core blocks the second inlet, and wherein, in either the first or the second position, the outlet remains open.

[0095] Clause 13. The method described in Clause 12, the method further comprising: A first valve retainer is inserted at a first intersection between the first fluid line and the manifold chamber. The first valve retainer includes a fourth fluid line communicating with the first fluid line and having a fourth inner radius substantially the same as the first inner radius. A second valve core retainer is inserted at the second intersection between the second fluid line and the manifold chamber. The second valve core retainer includes a fifth fluid line that communicates with the second fluid line and has a fifth inner radius that is substantially the same as the second inner radius.

[0096] Clause 14. The method described in Clause 12, the method further comprising: A sleeve is inserted into the manifold chamber, wherein the valve core is inserted into the sleeve before being inserted into the manifold chamber, and wherein the valve core slides longitudinally within the sleeve between the first position and the second position.

[0097] Clause 15. The method of Clause 12, wherein the integrally formed monolithic body is formed such that the first cross-section of the first inlet, the second cross-section of the second inlet, and the third cross-section of the outlet are manufactured to be substantially equal.

[0098] Clause 16. The method described in Clause 12, wherein the integrally formed monolithic body is formed such that: The outlet extends radially from the manifold chamber by a first distance, and The third fluid line has a bend at the first distance before terminating at the third connection region.

[0099] Clause 17. The method of Clause 16, wherein the integrally formed monolithic body is formed such that the third fluid line is bent such that the end region of the third fluid line is substantially parallel to the second fluid line of the second inlet.

[0100] Clause 18. The method described in Clause 17, the method further comprising: The integrally formed monolithic body is further formed such that the cut area is located between the outlet and the second inlet.

[0101] Clause 19. The method described in Clause 17, the method further comprising: The integrally formed monolithic body is further formed such that the filter is integrally formed with the outlet in the third fluid line and after the bend.

[0102] Clause 20. According to another aspect of this disclosure, an aircraft is provided, the aircraft comprising: body; A landing gear system, the landing gear system being connected to the fuselage; A hydraulic braking system connected to the landing gear system, wherein the hydraulic braking system includes a shuttle valve, the shuttle valve comprising: A first inlet, the first inlet having a first connection region communicating with a first fluid line, wherein the first fluid line includes a first inner radius substantially consistent along a first length of the first inlet; The second inlet has a second connection region communicating with a second fluid line, wherein the second fluid line includes a second inner radius that is substantially consistent along a second length of the second inlet; A manifold chamber, which is in communication with the first fluid line and opposite to the first connection area, and in communication with the second fluid line and opposite to the second connection area; An outlet having a third connection region communicating with a third fluid line, wherein the third fluid line communicates with the manifold chamber located between the first inlet and the second inlet, and wherein the third fluid line includes a third inner radius substantially consistent along a third length of the third fluid line; Valve core, the valve core being disposed in the manifold chamber; and A retaining feature is disposed in the manifold chamber and configured to retain the valve core in one of a first position and a second position, wherein, in the first position, a first end of the valve core blocks the first inlet, wherein, in the second position, a second end of the valve core blocks the second inlet, and wherein, in either the first position or the second position, the outlet remains open; The first inlet, the second inlet, the outlet, and the manifold chamber are integrated into a single unit.

[0103] Although the invention has been described with respect to a limited number of embodiments, those skilled in the art who benefit from this disclosure will understand that other embodiments can be devised without departing from the scope of the invention as disclosed herein.

Claims

1. A shuttle valve, the shuttle valve comprising: A first inlet, the first inlet having a first connection region communicating with a first fluid line, wherein the first fluid line includes a first inner radius substantially consistent along a first length of the first inlet; The second inlet has a second connection region communicating with a second fluid line, wherein the second fluid line includes a second inner radius that is substantially consistent along a second length of the second inlet; A manifold chamber, which is in communication with the first fluid line and opposite to the first connection area, and in communication with the second fluid line and opposite to the second connection area; An outlet having a third connection region communicating with a third fluid line, wherein the third fluid line communicates with the manifold chamber located between the first inlet and the second inlet, and wherein the third fluid line includes a third inner radius substantially consistent along a third length of the third fluid line; A filter, which is integrally formed with the outlet in the third fluid line; Valve core, the valve core being disposed in the manifold chamber; and A retaining feature is disposed in the manifold chamber and configured to retain the valve core in one of a first position and a second position, wherein, in the first position, a first end of the valve core blocks the first inlet, wherein, in the second position, a second end of the valve core blocks the second inlet, and wherein, in either the first position or the second position, the outlet remains open; The first inlet, the outlet, and the manifold chamber are integrally formed into a single body using additive manufacturing technology. The outlet has a continuous 90-degree flow path starting from the manifold chamber.

2. The shuttle valve according to claim 1, wherein, The first cross-section of the first inlet, the second cross-section of the second inlet, and the third cross-section of the outlet are substantially the same.

3. The shuttle valve according to claim 2, wherein: The outlet extends radially from the manifold chamber by a first distance, and The third fluid line has a bend at the first distance before terminating at the third connection region.

4. The shuttle valve according to claim 3, wherein, The third fluid line is bent such that the end region of the third fluid line is substantially parallel to the second fluid line at the second inlet.

5. The shuttle valve according to claim 4, further comprising: A cut area is provided between the outlet and the second inlet.

6. The shuttle valve according to claim 5, wherein, The filter is integrally formed with the outlet in the third fluid line and after the bend.

7. The shuttle valve according to claim 1, further comprising: Multiple mounting tabs are integrally formed on the outer side of the manifold chamber.

8. The shuttle valve according to claim 1, further comprising: A first valve core retainer is disposed at a first intersection between the first fluid line and the manifold chamber. The first valve core retainer includes a fourth fluid line that communicates with the first fluid line and has a fourth inner radius that is substantially the same as the first inner radius. as well as A second valve core retainer is disposed at a second intersection between the second fluid line and the manifold chamber. The second valve core retainer includes a fifth fluid line that communicates with the second fluid line and has a fifth inner radius that is substantially the same as the second inner radius.

9. The shuttle valve according to claim 1, further comprising: A sleeve is disposed within the manifold chamber, wherein the valve core slides longitudinally within the sleeve between the first position and the second position.

10. The shuttle valve according to claim 9, wherein, The retaining feature is disposed between the sleeve and the valve core.

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