Three-dimensional tortuous path flow element for controlling a valve

Abstract

A flow control element includes an element body formed as a unitary structure and disposed about a body axis. The element body includes a first surface, a second surface spaced apart from the first surface, and an inner peripheral surface extending between the first surface and the second surface and defining a central bore extending along the body axis. The element body also includes an outer peripheral surface extending between the first surface and the second surface in spaced relation to the inner peripheral surface. A plurality of channels extend between the inner peripheral surface and the outer peripheral surface, each channel having a pair of side surfaces extending in generally opposed relation to one another and a pair of ramp surfaces extending from respective ones of the pair of side surfaces toward one another.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Application No. 62 / 958,437, filed January 8, 2020, the contents of which are expressly incorporated by reference herein.

[0003] Statement as to Federally Sponsored Research / Development

[0004] Not Applicable TECHNICAL FIELD

[0005] The present disclosure relates generally to a flow control element, and more particularly, the present disclosure relates to a flow control element formed by additive manufacturing having a plurality of uniquely profiled flow control channels formed therein. BACKGROUND

[0006] Multi-stage trim in control valves are used to assist in pressure drop of fluid flowing through the control valve. Prior designs of such control valves include the use of reciprocating trim that moves within a series of stacked plates having flow paths connected with alternating longitudinal and transverse elements that form a tortuous flow path. The geometry of the flow paths can require that each flow path be segmented into its own volume space within the plates. As a result, to provide the required number of stages and flow, the plates can have a generally large outer diameter and vertical height, or valve stroke.

[0007] Stacked plate designs come in two general types. In one type, flow paths are formed by cutting in-plane bends on the plates. In the other type, flow paths are formed by cutting a series of offset slots in two mating plates to define a flow path that meanders or curves up and down from slot to slot. The offset type can utilize a third plate to separate adjacent flow paths. In both types, the plates can be joined together by brazing.

[0008] While stacked plate designs can be effective in forming the desired flow paths, there can be several associated drawbacks. For example, material utilization in forming conventional stacked plate designs can be relatively high. Along these lines, each flow path can require adjacent stock material to provide structural support during the manufacturing process and when assembled into the disc stack assembly in the valve. As a result, the material containing the flow paths far exceeds the material required to control flow and withstand working pressures.

[0009] Stacked disc designs can also require that the disc stack within the valve remain compressed. Compression can be achieved by transferring a portion of the bonnet bolt load from the surrounding valve housing to the disc stack. In valves with bolted bonnets, high cost precision machining of the valve body and trim can be required to maintain compression on the stacked discs. In valves with pressure energized bonnet seals, additional mechanical devices can be used to maintain compression on the stacked discs.

[0010] Accordingly, there is a need in the art for an improved multi-path flow control element that is not formed from stacked discs. Various aspects of the present disclosure address this particular need, as will be discussed in greater detail below. SUMMARY

[0011] The present disclosure relates to a multi-stage, multi-path flow control trim element that is optimized for additive manufacturing methods. The flow control trim includes a nested flow path that can reduce the outer diameter and / or height of the control trim by approximately 30% relative to conventional stacked discs. As a result, the size and cost of the control trim and control valve can be reduced.

[0012] According to one embodiment of the present disclosure, a flow control trim is provided that includes a trim body formed as a unitary structure and disposed about a body axis. The trim body includes a first surface, a second surface spaced apart from the first surface, and an inner peripheral surface extending between the first surface and the second surface and defining a central bore extending along the body axis. The trim body further includes an outer peripheral surface extending between the first surface and the second surface in spaced relation to the inner peripheral surface. A plurality of channels extend between the inner peripheral surface and the outer peripheral surface. Each channel has a pair of side surfaces extending in generally opposed relation to one another and a pair of angled surfaces extending from respective ones of the pair of side surfaces toward one another.

[0013] The plurality of channels can be arranged in a plurality of axial arrays, each array being parallel to the body axis. Each channel can include an opening at the outer peripheral surface, the openings of the channels in adjacent arrays being offset relative to one another in a direction parallel to the body axis.

[0014] Each channel can extend along at least two axes. Each side surface can include at least two segments that are angularly adjacent to one another to define an apex. The pair of side surfaces can include a first side surface having a first set of apexes aligned along a common axis. The pair of side surfaces can further include a second side surface having a second set of apexes aligned along the common axis.

[0015] A width of each channel can be defined as a perpendicular distance between the pair of side surfaces, wherein the width of each channel varies along the channel.

[0016] According to another embodiment, a method of forming a flow control element is provided. The method includes forming the element body in successive layers of material, each layer being integrally formed with the layer below.

[0017] The present disclosure can be better understood, when read in conjunction with the following detailed description and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0018] These and other features and advantages of the various embodiments disclosed herein will be better understood by reference to the following description and drawings, wherein:

[0019] Figure 1 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0020] Figure 2 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve; Figure 1 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0021] Figure 3 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve; Figure 2 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0022] Figure 4 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve; Figure 3 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0023] Figure 5 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve; Figure 4 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0024] Figure 6 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0025] Figure 7 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0026] Figure 8 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve; Figure 7 a top perspective view of a flow control element formed in accordance with an exemplary embodiment of the present disclosure, the flow control element integrated in a fluid control valve;

[0027] In all of the drawings and detailed description, like reference numerals refer to like elements. DETAILED DESCRIPTION

[0028] The detailed description set forth below in connection with the appended drawings is intended as a description of certain embodiments of the flow control element and is not intended to represent the only forms in which the present disclosure can develop. The description sets forth the features of the various embodiments, the specification and drawings should be considered in connection with the embodiments disclosed herein, but it should be understood that the same or equivalent

[0029] Referring now to the drawings, wherein the preferred embodiments of the present disclosure are illustrated by example, and not limitation, the drawings show a flow control element 10 having a plurality of three-dimensional tortuous flow passages 12 that can be particularly optimized for additive manufacturing methods. The configuration of the flow passages 12 can be configured to provide support for the flow control element 10 during the additive manufacturing process of the flow control element 10. The flow passages 12 can be arranged in a Russian nesting configuration within the flow control element 10, which can maximize the number of flow passages 12 within a given flow control element 10. The unique configuration of the flow control element 10 can allow the outer diameter and / or height of the flow control element 10 to be reduced by approximately 30% relative to conventional devices. As a result, reductions in the overall size and cost of the flow control element 10, and the corresponding control valve that houses the flow control element 10, can be realized. In this way, the flow control element 10 can be suitable for use in smaller flow control systems or flow control systems having space constraints.

[0030] Reference will now be made in detail to Figure 1 The flow control element 10 is shown incorporated in an example control valve 14 having a valve body 16. The valve body 16 includes an inlet 18, an outlet 20, and a gallery 22 located between the inlet 18 and the outlet 20. The flow control element 10 is located in the gallery 22 such that fluid passing from the inlet 18 to the outlet 20 passes through the flow control element 10. A valve plug 24 is positionable in a reciprocating manner relative to the flow control element 10 to control the amount of fluid that can pass through the flow control element 10, and thus the amount of fluid that can flow through the outlet 20. The valve plug 24 is included in the control valve 14 shown. Figure 1 The valve plug 24 shown in the control valve 14 is located inside the flow control element 10 and is raised to uncover the passages 12 formed in the flow control element 10 to allow fluid to pass therethrough. The valve plug 24 can be lowered relative to the valve plug 24 to cover the passages 12 formed in the flow control element 10 to prevent fluid from passing therethrough. Thus, by raising or lowering the valve plug 24, the amount of fluid passing through the flow control element 10 can be controlled. The valve plug 24 can be connected to an axially reciprocating valve stem 26 to facilitate selective raising and lowering of the valve plug 24 relative to the flow control element 10.

[0031] Referring now to the drawings Figure 2 The flow control element 10 includes an element body 28, which can be formed as a unitary structure, as described in greater detail below. The element body 28 can be a generally annular structure that defines a body axis 30 and thus is disposed about the body axis 30. The element body 28 has a first (top) surface 32 and an opposite second (bottom) surface 34. The element body 28 also includes an inner peripheral surface 34 and an outer peripheral surface 36, both of which extend between the first surface 32 and the second surface 34. The inner peripheral surface 34 defines a central bore that extends along the body axis 30, i.e., the axis 30 is also the axis of the central bore, which has a generally circular cross-sectional profile. From Figure 1 As can be seen in the exemplary control valve 14, the valve plug 24 is reciprocally movable within the central bore of the element body 28.

[0032] The plurality of passages 12 formed in the element body 28 extend between the inner peripheral surface 34 and the outer peripheral surface 36. Each passage 12 defines an inner opening 38 on the inner peripheral surface 34 and an outer opening 40 on the outer peripheral surface 36. Each passage 12 can also define a tortuous configuration between the inner opening 38 and the outer opening 40, and thus each passage 12 can extend along or parallel to at least two axes. The tortuous configuration results in a series of bends or twists of each passage 12 between the inner peripheral surface 34 and the outer peripheral surface 36.

[0033] The passages 12 can be arranged in a manner that optimizes the space on the flow control element 10 while also allowing additive manufacturing of the flow control element 10 (e.g., forming the flow control element 10 in a layer-by-layer manner). In one embodiment, the passages 12 can be arranged in a plurality of axial arrays. In Figure 2 In the illustrated embodiment, the passages 12 are vertically aligned in arrays in the axial direction around the circumference of the flow control element 10. In other words, when viewed from the perspective view shown in Figure 2 The passages 12 appear as an array of a plurality of generally vertical columns across the circumference of the element body 28, with the passages 12 in each such column being vertically aligned with one another, when viewed from the perspective view shown in FIG. 2. Each of these columns extends along a respective column axis that is generally parallel to the body axis 30. In this regard, for a given array or column of passages 12, the inner openings 38 of each passage 12 in the array extend along a common inner axis that is generally parallel to the column axis and the axis 30. In a similar manner, the outer openings 40 of each passage 12 in the array extend along a common outer axis that is generally parallel to the column axis and the axis 30. In this way, in each array or column, the passages 12 can be stacked on top of one another. To illustrate the configuration of the arrays, in Figure 2In the illustrated embodiment, the first array is aligned with the first column axis 42 and the second array is aligned with the second column axis 44. As can be seen, these arrays are spaced apart from one another and are located on the entire circumference of the element body 28.

[0034] It is contemplated that the arrangement of passages 12 in one array or column can be slightly spaced, offset, or staggered relative to the arrangement of passages 12 in an adjacent array or column. In other words, the passages 12 in adjacent arrays can be slightly offset relative to one another in a direction parallel to the body axis 30. In this regard, due to this offset arrangement, a given circumferential axis that is perpendicular to the body axis 30 can pass through one passage 12 without passing through an adjacent passage 12. The offset configuration of the passages 12 can result in the passages 12 appearing as a generally helical or spiral array, for example, as viewed from the perspective Figures 2 to 4 illustrated perspective view. In other words, the offsetting or staggering of the passages 12 can result in the passages 12 being aligned along a helical axis that extends around the element body 28.

[0035] The offsetting or staggering of the passages 12 in adjacent arrays can eliminate or reduce coplanar gaps and dead zones when the valve plug 24 is opened or closed within the valve 14. For example, as the valve plug 24 is raised or lowered within the central bore of the flow control element 10, the passages 12 in adjacent arrays can be covered or opened sequentially, rather than simultaneously.

[0036] Although the exemplary embodiment of the flow control element 10 includes passages 12 that are offset or staggered in the manner described above, the scope of the present disclosure is not limited in this regard. Thus, in other embodiments, it is contemplated that the passages 12 in adjacent arrays or columns can be aligned such that, when viewed from a perspective similar to Figure 2 illustrated, the passages 12 in these adjacent arrays or columns appear as a series of stacked, generally circular rows, each row extending along a respective common circumference about the axis 30. Thus, in this alternative arrangement, and again with reference to the perspective view Figure 2 illustrated, the passages 12 are vertically aligned with the passages in the same column, and are also horizontally aligned with the passages in the same circumferential row.

[0037] Figure 3 For a vertical cross-sectional view of the element body 28, illustrating the internal structure of the passages 12 aligned along a common vertical column or array, the dashed arrows represent an exemplary fluid flow through each passage 12, with the fluid flowing in a radially outward direction.

[0038] Figure 4This is a partial upper perspective view of a flow control element 10, where various channels 12 are shown in dashed lines, indicating the internal nesting and arrangement of channels 12 within the element body 28. The channels 12 may be constructed identically or substantially similar to allow them to nest adjacent to each other, thereby maximizing the number of channels 12 that can be adapted within the flow control element 10. For example, a channel 12 may include a protruding or raised section nested within an inwardly extending or recessed section of an adjacent channel 12.

[0039] For reference Figures 5 to 8 Each channel 12 may have a configuration that facilitates obtaining desired fluid properties of the fluid flowing through it, and allows the channels 12 to be nested together in a structure formed by additive manufacturing technology. According to one embodiment, and according to... Figures 2 to 4 and Figure 6 The perspective view / reference frame shown indicates that each channel 12 includes a base surface 46, a pair of side surfaces 48, 50, and a pair of inclined surfaces 52, 54. The base surface 46 may be generally planar and extend perpendicularly to the body axis 30. The pair of side surfaces 48, 50 may both extend from the base surface 46 in a generally opposite relationship to each other. In one embodiment, the side surfaces 48, 50 are structurally similar and generally parallel to each other. Figure 6 As shown, it is conceivable that, according to the preferred additive manufacturing process applied to the auxiliary manufacturing of the flow control element 10, the junction between the base surface 46 and the corresponding side surfaces 48, 50 will not be defined by a sharp 90-degree angle. Instead, each transition region will have an arcuate or curved profile.

[0040] Inclined surfaces 52 and 54 extend from their respective side surfaces 48 and 50. Inclined surfaces 52 and 54 extend toward each other to define a peak at their intersection. Figure 6 As further illustrated, it is conceivable that, according to a preferred additive manufacturing process used to assist in the manufacture of the flow control element 10, the junction between the beveled surfaces 52, 54 will not be defined by a sharp 90-degree angle. Instead, the aforementioned transition region or peak will have an arcuate or curved profile. The shape and arrangement of the beveled surfaces 52, 54 can help provide strength and structural integrity to the corresponding channels 12, especially during the manufacture of the flow control element 10. Furthermore, the beveled surfaces 52, 54 can provide structural support for the stacked channels 12 within the flow control element 10.

[0041] Side surfaces 48 and 50 define the width W of channel 12 as the distance between side surfaces 48 and 50 in a direction perpendicular to the two side surfaces 48 and 50. The width W of channel 12 can vary along channel 12, thus including narrow and wide portions to facilitate desired fluid characteristics. Figure 8In the illustrated example embodiment, the width increases from the inside out (i.e., from the interior opening 38 at the inner peripheral surface 34 to the exterior opening 40 at the outer peripheral surface 36) to control fluid expansion. In this regard, the passage 12 can define a first width W1 at the interior opening 38 and a second width W2 greater than the first width at the exterior opening 40. However, depending on the direction of fluid flow through the control valve 14 in which the flow control element 10 is integrated, it is contemplated that an inverse configuration can also be employed in which the width increases from the outside in (i.e., from the exterior opening 40 at the outer peripheral surface 36 to the interior opening 38 at the inner peripheral surface 34).

[0042] Reference will now be made to Figure 8 As noted above, each passage 12 is defined in part by the first side surface 48 and the second side surface 50. The first side surface 48 includes an inner section 56 proximate the end opening (interior or exterior) of width W1 and an outer section 62 proximate the end opening (interior or exterior) of width W2. A plurality of intermediate sections 60 extend between the inner section 56 and the outer section 62. With respect to a common reference axis 64, the inner section 56 is coincident with the common axis 64, while the intermediate sections 60 and the outer section 62 each extend at a prescribed angle with respect to the common axis 64. Adjacent pairs of intermediate sections 60 can define a series of apex points A 1-3 and valley points V 1-4 Each apex point A 1-3 and each valley point V 1-4 is defined by an adjacent pair of intermediate sections 60. The apex points A 1-3 define a first set of apex points that can be positioned to lie on the common axis 64. Each valley point V 1-4 may be spaced apart from the common axis 64 by a respective distance d. In particular, the valley point V1 is spaced apart from the common axis 64 by a distance dl, the valley point V2 is spaced apart from the common axis 64 by a distance d2, the valley point V3 is spaced apart from the common axis 64 by a distance d3, and the valley point V4 is spaced apart from the common axis 64 by a distance d4. The size of dl is less than d2, d2 is less than d3, d3 is less than d4. In this regard, the valley points V 1-4 are spaced apart from the common axis 64 by a distance that increases with increasing distance from the end opening (interior or exterior) of width W1.

[0043] The second side surface 50 is similar to the first side surface 48. In particular, the second side surface 50 includes an inner section 66 proximate the end opening (either internal or external) of width Wl and an outer section 70 proximate the end opening (either internal or external) of width W2. A plurality of intermediate sections 68 extend between the inner section 66 and the outer section 70. The inner section 66 extends in spaced, generally parallel relation to the common axis 64, while the intermediate sections 68 and the outer section 70 each extend at a prescribed angle relative to the common axis 64. Adjacent pairs of intermediate sections 68 can define a series of apexes A 4-7 and valleys V 5-7 each apex A 4-7 and each valley V 5-7 defined by the adjacent pairs of intermediate sections 68. The apexes A 4-7 define a second set of apexes that can be positioned to lie on the common axis 64. Each valley V 5-7 may be spaced a respective distance d from the common axis 64. In particular, the valley V5 is spaced a distance d5 from the common axis 64, the valley V6 is spaced a distance d6 from the common axis 64, and the valley V7 is spaced a distance d7 from the common axis 64. The distance d5 is smaller than the distance d6, which is smaller than the distance d7. In this regard, the valleys V 5-7 are spaced a distance from the common axis 64 that increases as the distance from the end opening (either internal or external) of width Wl increases.

[0044] By configuring the channels 12 such that all of the apexes A 1-7 of both side surfaces 48, 50 lie on the common axis 64, the flow of fluid through the middle of the channels 12 is prevented from being constant and linear. Thus, all of the fluid flowing through the channels 12 is forced to change course as it flows through the tortuous configuration, thereby facilitating the desired pressure drop in the fluid. Those of ordinary skill in the art will recognize that, although each channel 12 is tortuous, it can alternatively be configured such that its width is constant along its entire length (i.e., between the internal and external openings defined thereby), such that there is no variation between dl-d7.

[0045] In addition to the variation in the width W of the channels 12, it is contemplated that a variation in the height of the channels 12 can also be incorporated into the flow control element 10 to facilitate the desired fluid characteristics of the fluid flowing through the channels 12. The height H of the channels 12 can refer to the distance between the base surface 46 and the apex 55 defined by the angled surfaces 52, 54. The height H of the channels 12 can vary along the channels 12 to include low portions and high portions, thereby facilitating the desired fluid characteristics. In Figure 7In the example embodiment shown, the height H increases from the inside out (i.e., from the interior opening 38 at the inner peripheral surface 34 to the exterior opening 40 at the outer peripheral surface 36) to control fluid expansion. In this regard, the passage 12 can define a first height H1 at the interior opening 38 and a second, greater height H2 at the exterior opening 40. However, depending on the direction of fluid flow through the control valve 14 in which the flow control element 10 is integrated, it is contemplated that an opposite configuration can also be employed in which the height H increases from the outside in (i.e., from the exterior opening 40 at the outer peripheral surface 36 to the interior opening 38 at the inner peripheral surface 34).

[0046] The configuration of the flow control element 10 can reduce the overall size of the flow control element 10 relative to conventional flow control elements formed from a stack of discs by significantly reducing the amount of material used to house the passage 12. In this regard, the size of the control valve 14 in which the flow control element 10 is housed can be reduced. Moreover, the reduced size can facilitate installation of the tortuous path valve in facilities having strict space constraints, such as offshore platforms and marine vessels.

[0047] Various embodiments of the flow control element 10 described above can be formed by additive manufacturing, which can include, but is not limited to, 3D printing, laser sintering, or other layer-by-layer manufacturing techniques known to those skilled in the art or later developed. In this vein, for example, in Applicant’s U.S. Patent No. 8,826,938, forming techniques are described that can potentially be used to assist in the manufacture of the flow control element 10, the disclosure of which is incorporated herein by reference.

[0048] The details shown herein are shown by way of example for illustrative discussion purposes only and are not presented in order to provide what is believed to be the most useful and readily understood description of the principles and conceptual aspects of various embodiments of the present disclosure. In this regard, no attempt is made to show any more details than are necessary in order to convey a thorough understanding of the different features of the various embodiments to one skilled in the art, in connection with the drawings.

Claims

1. A flow control element comprising: an element body formed as a unitary structure and disposed about a body axis, and having: a first surface; a second surface spaced apart from the first surface; an inner peripheral surface extending between the first and second surfaces and defining a central bore extending along the body axis; an outer peripheral surface extending between the first and second surfaces in spaced relation to the inner peripheral surface; and a plurality of channels extending between the inner and outer peripheral surfaces, the plurality of channels presenting an array of generally vertical columns on each of the inner and outer peripheral surfaces, with the channels in each column vertically aligned with one another and positioned along a column axis that is generally parallel to the body axis, with the channels in any one column slightly offset relative to the channels in any adjacent column in a direction generally parallel to the body axis, such that the channels present a generally helical array about the element body on each of the inner and outer peripheral surfaces, with the channels aligned along a helical axis about the element body. Each channel extends along at least two axes.

2. The flow control element of claim 1, wherein, Each channel has a pair of side surfaces extending in generally opposed relation to one another and a pair of ramp surfaces extending from respective ones of the pair of side surfaces toward one another.

3. The flow control element of claim 2, wherein, A width of each channel is defined as a perpendicular distance between the pair of side surfaces, each channel being configured such that the width varies along the channel.

4. The flow control element of claim 3, wherein, 5. A fluid control valve comprising: a valve housing having a fluid inlet and a fluid outlet; a flow control element disposed within the valve housing between the fluid inlet and the fluid outlet, the flow control element formed as a unitary structure and disposed about a body axis, the flow control element having: a first surface; a second surface spaced apart from the first surface; an inner peripheral surface extending between the first and second surfaces and defining a central bore extending along the body axis; an outer peripheral surface extending between the first and second surfaces in spaced relation to the inner peripheral surface; and a plurality of channels extending between the inner and outer peripheral surfaces, each channel having a pair of side surfaces extending in generally opposed relation to one another and a pair of ramp surfaces extending from respective ones of the pair of side surfaces toward one another, the plurality of channels presenting an array of generally vertical columns on each of the inner and outer peripheral surfaces, with the channels in each column vertically aligned with one another and positioned along a column axis that is generally parallel to the body axis, with the channels in any one column slightly offset relative to the channels in any adjacent column in a direction generally parallel to the body axis, such that the channels present a generally helical array about the element body on each of the inner and outer peripheral surfaces, with the channels aligned along a helical axis about the element body. ​ ​ 6. The fluid control valve of claim 5, wherein, The plurality of channels are arranged in a plurality of axial arrays, each array being parallel to the body axis.

7. The fluid control valve of claim 6, wherein, Each channel includes an opening at an outer peripheral surface, the openings of the channels in adjacent arrays being offset relative to one another in a direction parallel to the body axis.

8. The fluid control valve of claim 5, wherein, Each channel extends along at least two axes.

9. The fluid control valve of claim 8, wherein, Each side surface includes at least two intermediate segments that are angularly adjacent to one another and define a vertex therebetween.

10. The fluid control valve of claim 9, wherein, The pair of side surfaces includes a first side surface having a first set of vertices aligned along a common axis.

11. The fluid control valve of claim 10, wherein, The pair of side surfaces includes a second side surface having a second set of vertices aligned along the common axis.

12. The fluid control valve of claim 5, wherein, A width of each channel is defined as a perpendicular distance between the pair of side surfaces, each channel being configured such that the width varies along the channel.

13. A flow control element comprising: an element body formed as a unitary structure and disposed about a body axis, the element body including: a first surface; a second surface spaced apart from the first surface; an inner peripheral surface extending between the first and second surfaces and defining a central bore extending along the body axis; an outer peripheral surface extending between the first and second surfaces in spaced relation to the inner peripheral surface; and a plurality of channels extending between the inner and outer peripheral surfaces, each channel having an inner opening in the inner peripheral surface and an outer opening in the outer peripheral surface, each channel having a pair of side surfaces extending in generally opposed relation to one another and a pair of angled surfaces extending from respective ones of the pair of side surfaces toward one another to define a vertex having an arcuate configuration, the plurality of channels appearing as an array of generally vertical columns on each of the inner and outer peripheral surfaces with the channels in each column being vertically aligned with one another and positioned along a column axis that is generally parallel to the body axis, with the channels in any column being slightly offset relative to corresponding inner and outer openings of the channels in any adjacent column in a direction generally parallel to the body axis such that the channels appear as a generally helical array about the element body on each of the inner and outer peripheral surfaces with the channels being aligned along a helical axis about the element body.

14. The flow control element of claim 13, wherein, Each channel extends along at least two axes.

15. The flow control element of claim 14, wherein, Each side surface includes at least two intermediate segments that are angularly adjacent to one another and define a vertex therebetween.

16. The flow control element of claim 15, wherein, The pair of side surfaces includes a first side surface having a first set of vertices aligned along a common axis.

17. The flow control element of claim 16, wherein, The pair of side surfaces includes a second side surface having a second set of vertices aligned along the common axis.

18. The flow control element of claim 13, wherein, A width of each channel is defined as a perpendicular distance between the pair of side surfaces, each channel being configured such that the width varies along the channel.

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