Valve cage with grid structure

Abstract

The invention discloses a valve cage with a grid structure. An example cage includes a first end, a second end opposite the first end, and a wall between the first end and the second end. The walls include a skeleton frame having a plurality of frame walls extending between a first end and a second end. The skeleton frame defines a plurality of windows. The wall also includes a grid structure in the window.

Description

Technical Field

[0001] This disclosure relates generally to valves and valve components, and more specifically to valve cages having a lattice structure. Background Technology

[0002] Valves are commonly used in process control systems to control the flow of process fluids (e.g., water, gas, etc.). Sliding rod valves (e.g., gate valves, globe valves, diaphragm valves, pinch valves, etc.) typically have a closing member (e.g., a valve plug) disposed within the valve's fluid passage. The valve stem operably couples the closing member to an actuator to move the closing member between an open and closed position, thereby allowing or restricting fluid flow between the valve's inlet and outlet. Additionally, to provide desired fluid flow characteristics and / or achieve certain fluid flow properties, valves often employ a cage inserted into the fluid passage. The closing member is disposed within the cage and can move within it. The cage can be used to reduce flow capacity, attenuate noise, and / or reduce or eliminate cavitation. Summary of the Invention

[0003] An exemplary cage for a valve includes: a first end, a second end opposite the first end, and a wall between the first and second ends. The wall includes a skeleton frame having a plurality of frame walls extending between the first and second ends. The skeleton frame defines a plurality of windows. The cage wall also includes a mesh structure within the windows.

[0004] An exemplary valve includes: a valve body defining a fluid passage between an inlet and an outlet; a plug; and a valve cage within the fluid passage. The plug is disposed within the cage. The plug is movable within the cage to control fluid flow through the fluid passage. The cage includes a first end, a second end, and a wall between the first and second ends. The wall includes a mesh structure and a skeleton frame having a plurality of frame walls extending into the mesh structure. The inner diameter of the skeleton frame is smaller than the inner diameter of the mesh structure.

[0005] An exemplary method includes constructing a cage for a valve via an additive manufacturing process. The cage includes a first end, a second end opposite the first end, and a wall between the first and second ends. The wall includes a skeleton frame extending between the first and second ends and defining a plurality of windows. The wall includes a mesh structure within the windows. Attached Figure Description

[0006] Figure 1 This is a cross-sectional view of an exemplary valve in which the exemplary cage disclosed herein may be implemented.

[0007] Figure 2 This is a perspective view of an example cage having an exemplary grid structure and an exemplary skeleton frame with spiral frame walls.

[0008] Figure 3 yes Figure 2 An enlarged view of the inner surface of an exemplary cage.

[0009] Figure 4A , Figure 4B and Figure 4C It shows that it can be used Figure 2 The exemplary mesh structure used in the exemplary cage.

[0010] Figure 5 It has no mesh structure Figure 2 A side view of a portion of an exemplary cage.

[0011] Figure 6 yes Figure 2 A cross-sectional view of an exemplary cage.

[0012] Figure 7A yes Figure 6 A cross-sectional view, wherein an exemplary plug is placed in an exemplary cage.

[0013] Figure 7B yes Figure 7A The enlarged view of the annotations in the figure shows an exemplary flowline through the exemplary cage.

[0014] Figure 8 yes Figure 2 A perspective view of an exemplary cage, wherein the exemplary skeleton frame has enlarged vertical frame walls.

[0015] Figure 9 This is a perspective view of another exemplary cage having an exemplary skeleton frame with spiral frame walls.

[0016] Figure 10 It is an enlarged view of the inner surface of another exemplary cage having another exemplary skeleton frame with spiral frame walls and no vertical frame walls.

[0017] Figure 11 This is an external view of an exemplary cage, wherein the exemplary skeleton frame does not extend through the exemplary mesh structure.

[0018] Figure 12 A portion of an exemplary cage with an exemplary skeleton frame having polygonal frame walls is shown.

[0019] Figure 13 A portion of an exemplary cage with an exemplary skeleton frame having polygonal frame walls is shown.

[0020] Figure 14 An exemplary additive manufacturing machine is shown that can be used to form any of the exemplary cages disclosed herein.

[0021] Figure 15 This is a flowchart illustrating an exemplary method for manufacturing an exemplary cage.

[0022] Generally, the same reference numerals will be used throughout the accompanying drawings and written description to refer to the same or similar parts. The drawings are not drawn to scale.

[0023] Unless otherwise specified, descriptors such as “first,” “second,” “third,” etc., are used herein without imposing or otherwise indicating any meaning of priority, physical order, arrangement in a list, and / or any sorting, but merely as labels and / or arbitrary names to distinguish elements for the purpose of understanding the disclosed examples. In some examples, the descriptor “first” may be used to refer to an element in a particular embodiment, while the same element may be referred to in the claims by different descriptors (such as “second” or “third”). In such cases, it should be understood that such descriptors are only used to clearly identify those elements that may, for example, otherwise share the same name. Detailed Implementation

[0024] Many known process control and / or fluid distribution systems (e.g., power generation systems, refinery systems, etc.) employ process control devices to influence the flow of fluids. For example, valves are a common type of process control device used to control the flow of fluids (e.g., liquids, gases, etc.) between an upstream source and a downstream location. Some known valves, such as lever valves (e.g., gate valves), include a plug that can move relative to a seat (e.g., a seal) between an open position and a closed position. When the plug is in the open position, it disengages from the seat and allows fluid to flow from the valve's inlet to its outlet. When the plug is in the closed position, it engages with the seat and prevents fluid flow between the inlet and outlet. The opening and closing of the valve can be performed manually or via a control actuator with a command signal to move the plug.

[0025] When a valve is in the open position, the restriction of flow through the valve increases the fluid velocity but decreases the fluid pressure. If the pressure drops below the fluid's vapor pressure, vapor bubbles form. When the pressure recovers downstream, these vapor bubbles implode, resulting in a high-pressure wave. This phenomenon, known as cavitation, can cause significant damage to the valve and downstream piping in the form of corrosion. Damage to the valve due to cavitation can cause it to lose its sealing ability. Furthermore, cavitation can lead to other adverse effects such as high noise and strong vibration.

[0026] Noise can also be generated by valves and other control valves due to turbulence. As fluid flows through the constriction of an open valve, its velocity increases while its pressure decreases. When the high-speed fluid leaves the valve, it interacts with relatively stationary or low-speed fluid at the valve outlet. This fluid interaction occurs at a shear layer between the high-speed and stationary or low-speed fluids. In this situation, noise is caused by turbulent pressure fluctuations within the shear layer.

[0027] In some examples, the valve may be equipped with an internal component including a cage to control noise and cavitation of the fluid flowing through the valve. The cage is a cylindrical or sleeve-shaped structure disposed within the fluid passage. A plug is disposed within the cage and is movable (e.g., slidable) within the cage. The cage has openings (e.g., orifices, slots, etc.) through which fluid travels when the plug is in the open (or partially open) position. The cage reduces noise caused by the flowing fluid. Furthermore, the cage reduces or isolates damage from cavitation. The openings in the cage through which fluid travels cause jet separation of the fluid traveling through the valve. Cavitation is isolated by using a downward flow orientation to direct fluid towards the center of the valve, causing bubbles to implode away from the valve components, thereby minimizing damage to the valve components.

[0028] This document discloses an exemplary cage having walls at least partially constructed of a mesh structure. The mesh structure comprises a network of voids that form or define openings (flow paths) through the cage walls. The use of a mesh structure allows for the formation of relatively small-diameter openings (e.g., 1 / 16 inch or smaller) in the cage walls for fluid flow. Smaller-diameter openings produce noise consisting of higher acoustic frequencies compared to larger-diameter openings. Human hearing ranges from 20 to 20,000 Hz. Therefore, using smaller-diameter openings tends to shift noise frequencies to frequencies that are less or not heard by the human ear. Thus, the use of a mesh structure helps to significantly reduce noise generated by flowing fluids. The size of the openings can be determined based on application needs to achieve desired noise attenuation, cavitation reduction, flow capacity, and other parameters.

[0029] The exemplary cage disclosed herein also includes an exemplary skeleton frame in the cage walls. The exemplary skeleton frame includes multiple frame walls arranged in a specific pattern to form multiple windows (e.g., larger openings). A mesh structure is formed in each window. In other words, the skeleton frame extends at least partially into the mesh structure (in the radial direction). The inner diameter of the skeleton frame is smaller than the inner diameter of the mesh structure. Thus, the skeleton frame forms an internal guiding surface along which the plug slides. Therefore, the plug does not slide or contact the mesh structure. Therefore, the mesh structure does not need to be machined or smoothed. Machining or smoothing the mesh structure can sometimes clog the openings, complicating the manufacturing and machining processes. Therefore, using a skeleton frame to provide a guiding surface reduces manufacturing time and cost. Furthermore, the skeleton frame provides strength to the cage, which reduces the load on the mesh during valve manufacturing, assembly, and operation. Exemplary skeleton frames with different patterns or arrangements of frame walls (such as spirals and polygons) are disclosed herein. The frame walls define a repeating pattern of windows, which can have different shapes depending on the arrangement of the frame walls.

[0030] The exemplary skeleton frame disclosed herein also reduces unwanted gap flow and upward flow through the valve cage. The skeleton frame has an inner diameter smaller than the mesh, which can be machined to have relatively small tolerances between the plug and the cage. For example, when the plug is in the partially open position, the bottom of the plug may be aligned with the center of one of the windows in the window. Therefore, some fluid may flow between the plug and the mesh structure and upward along the gap between the plug and the mesh structure. However, the frame walls of the skeleton frame prevent flow from moving to other windows above the bottom of the plug. Thus, the frame walls of the skeleton frame reduce or restrict gap flow. Furthermore, the skeleton frame may extend radially through the mesh structure, which reduces upward flow while simultaneously radially moving through the cage, sometimes referred to as upward flow. For example, when the plug is in the partially open position, the bottom of the plug may be aligned near the top of one of the windows in the window. The frame walls of the skeleton frame prevent or restrict radial flow through the cage from also moving upward to the window above the bottom of the plug.

[0031] In some of the examples disclosed herein, the cages are constructed via additive manufacturing processes (sometimes referred to as 3D printing). As used herein, additive manufacturing or 3D printing refers to a manufacturing process that builds a 3D object by adding successive layers of adjacent material. These layers are fused together (e.g., naturally or via a subsequent fusion process) to form the 3D object. The material can be any material, such as plastics, metals, concrete, etc. Examples of additive manufacturing include stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), and multi-jet molding (MJM). 3D printing is advantageous because it results in less material waste than known machining operations. Therefore, 3D-printed cages result in cages of relatively low cost. Furthermore, 3D printing is advantageous because it can be used to form high-density features, such as mesh structures with small openings (flow paths), which may be infeasible with other known machining processes.

[0032] Figure 1 This is a cross-sectional view of an exemplary valve 100 constructed in accordance with the teachings of this disclosure. Valve 100 can be used to control the flow of fluids such as liquids or gases. Valve 100 is a type of slide valve, such as a shut-off valve. In other examples, valve 100 may be implemented as another type of valve.

[0033] In the example shown, valve 100 includes a valve body 102 that defines a fluid passage 104 between an inlet 106 and an outlet 108. Valve body 102 can be coupled between two pipes and is used to control fluid flow between an upstream source and a downstream region. In some examples, valve body 102 includes multiple body portions coupled together. For example, in... Figure 1 In this example, valve body 102 has a first body portion 110 and a second body portion 112 (sometimes referred to as a valve cover) coupled to the first body portion 110. In the example shown, the second body portion 112 is coupled to the first body portion 110 via one or more threaded fasteners 114 (e.g., bolts).

[0034] In the example shown, valve 100 includes an exemplary seat 116 disposed in a fluid passage 104. Valve 100 also includes an exemplary valve plug 118. In some examples, plug 118 is a countersunk plug. Valve 100 includes an exemplary rod 120 extending through a second body portion 112 and coupled to plug 118 in the fluid passage 104. Rod 120 may be coupled to an actuator (e.g., a pneumatic actuator, etc.) or a manually operated device (e.g., a handwheel). In operation, the actuator moves rod 120 up and down to move valve plug 118 between an open position and a closed position. In the open position (which is... Figure 1In the position shown, the plug 118 is spaced apart from the seat 116, which allows fluid to flow through the fluid passage 104 between the inlet 106 and the outlet 108. In the closed position, the plug 118 engages with the seat 116 to form a seal that prevents fluid from flowing through the seat 116 and thus through the fluid passage 104 between the inlet 106 and the outlet 108.

[0035] In the example shown, valve 100 includes an exemplary cage 122 disposed in a fluid passage 104. In this example, cage 122 is cylindrical or sleeve-shaped. Cage 122 defines a central orifice or passage 124. A plug 118 is disposed in the passage 124 of cage 122. Plug 118 is movable up and down (e.g., slidable) within the passage 124 of cage 122 to control fluid flow through fluid passage 104. Cage 122 has a wall 126 with multiple openings. When plug 118 is in the open (or partially open) position, fluid flows through seat 116, into passage 124, and through one or more openings in the wall 126 of valve cage 122 to reach outlet 108, as indicated by the dashed arrow lines. The size, shape, and / or layout of the openings can be designed to reduce noise and cavitation. When plug 118 is in the closed position, plug 118 engages seat 116, which prevents fluid from flowing into passage 124 of valve cage 122.

[0036] In the example shown, cage 122 is coupled to valve body 102. In some examples, cage 122 is clamped between two portions of valve body 102. For example, to install cage 122, second body portion 112 is separated from first body portion 110, cage 122 is inserted into fluid passage 104, and then second body portion 112 is reattached to first body portion 110, clamping cage 122 between first body portion 110 and second body portion 112. In other examples, valve cage 122 may be coupled to valve body 102 in other ways.

[0037] Figure 2 This is a perspective view of an exemplary cage 200 constructed in accordance with the teachings of this disclosure. The example cage 200 can be implemented as follows: Figure 1 An exemplary cage 122 in the example valve 100. Cage 200 has multiple parts or sections, as disclosed in further detail herein. In some examples, the entire cage 200 is constructed as a single integral part or component (e.g., an integral structure). However, in other examples, cage 200 may be constructed as separate parts or sections coupled together during the assembly process (e.g., via welding, fasteners, etc.).

[0038] In the example shown, cage 200 includes a first end 202, a second end 204 opposite to the first end 202, and a wall 206 between the first end 202 and the second end 204. Depending on the orientation of cage 200, the first end 202 and the second end 204 may be referred to as the upper end and the lower end. Cage 200 has a central channel 208 between the first end 202 and the second end 204. Plug 118 ( Figure 1 The cage 200 is to be positioned in the central channel 208. In this example, the cage 200 is cylindrical and has a central axis 210. As used herein, the terms “axial” and “longitudinal” refer to directions parallel to the central axis 210, “radial” refers to directions perpendicular to the axial direction, and “tangential” or “circumferential” refers to directions perpendicular to both the axial and radial directions.

[0039] In the example shown, the first end 202 and the second end 204 are solid materials, while the wall 206 has a plurality of openings 212 (one of which is in Figure 2 (Referenced in [reference]). Specifically, wall 206 has an inner side 214 and an outer side 216. An opening 212 is formed through wall 206 between the inner side 214 and the outer side 216. The opening 212 defines a flow path for fluid to flow through wall 206 of cage 200. In some examples, the first end 202 and the second end 204, as well as wall 206, are made of the same material (such as metal). In some examples, cage 200 is constructed via an additive manufacturing process (sometimes referred to as 3D printing). For example, cage 200 can be 3D printed as a single integral part or component by melting multiple layers of material together.

[0040] Figure 3 This is an enlarged view of the inner side 214 of cage 200. Described together in this document... Figure 2 and Figure 3 .like Figure 2 and Figure 3 As shown, the wall 206 of the cage 200 includes a skeletal frame 218 extending between a first end 202 and a second end 204. The skeletal frame 218 includes a plurality of frame walls 220 extending between the first end 202 and the second end 204 (one of which is in…). Figure 2 and Figure 3 (As cited herein). Frame walls 220 can be arranged in various patterns, which are disclosed in further detail herein. Frame walls 220 are made of a solid material (e.g., steel). Frame walls 220 of the skeleton frame 218 form or define a plurality of openings 222, referred to herein as windows 222. One of the exemplary windows 222 is shown in... Figure 2 and Figure 3Each of the elements is marked. In this example, the frame wall 220 is arranged such that the window 222 has a rhomboid shape (which may also be referred to as a rhomboid shape). In other examples, the window 222 may be shaped differently, examples of which are disclosed in further detail herein. The skeleton frame 218 has many advantages, such as for the plug 118 ( Figure 1 It provides a guiding surface, provides strength to the cage 200, and reduces (e.g., minimizes) gap flow.

[0041] exist Figure 2 and Figure 3 In the example shown, wall 206 includes a grid structure 224 in window 222 (in Figure 2 and Figure 3 (Each of these references is cited once). Specifically, a mesh structure 224 is formed or constructed between the frame walls 220 in each window 222. The mesh structure 224 forms openings 212 through the walls 206. In particular, the mesh structure 224 has small interconnecting units or voids forming the openings 212, thereby defining fluid channels through the walls 206 of the cage 200. In some examples, the mesh structure 224 is a triple periodic mesh structure (sometimes referred to as a triple periodic minimum surface (TPMS) mesh structure). Figure 4A , Figure 4B and Figure 4C Three examples of a triple periodic mesh structure that can be implemented as mesh structure 224 are shown. Figure 4A An exemplary mesh structure with spiral-shaped units is shown. Figure 4B An exemplary grid with diagonal square cells is shown, and Figure 4C An exemplary mesh with original shape cells is shown. The cell size and volume fraction of the mesh structure can be configured based on desired flow characteristics. In some examples, the mesh can be hierarchical, such that the mesh can have a high volume fraction for low flow capacities and a low volume fraction for higher flow capacities.

[0042] Return to reference Figure 2 and Figure 3 The skeleton frame 218 has a smaller inner diameter than the mesh structure 224. In other words, the inner surface 226 of the skeleton frame 218 extends radially inward further than the mesh structure 224. Therefore, the inner surface 226 of the skeleton frame 218 forms a guiding or sliding surface along which the plug 118 can slide within the cage 200. In this way, the plug 118 will not engage with or slide against the mesh structure 224. Therefore, the mesh structure 224 does not need to be machined or smoothed, which reduces manufacturing time and cost. The skeleton frame 218 also provides strength to the cage 200.

[0043] Therefore, wall 206 can be considered as being formed by a skeleton frame 218 extending between the first end 202 and the second end 204, wherein the mesh structure 224 is within the window 222 of the skeleton frame 218. In other examples, wall 206 can be considered as being formed by a mesh structure 224 extending between the first end 202 and the second end 204, wherein the skeleton frame 218 extends at least partially into the mesh structure 224 (in the radial direction). In some examples, the skeleton frame 218 extends completely through the mesh structure 224. However, in other examples, the skeleton frame 218 extends only partially into the mesh structure 224, examples of which are shown in [examples of other examples]. Figure 11 As shown in the image.

[0044] Figure 5 This is a side view of a portion of cage 200, showing the skeleton frame 218 without the grid structure 224. In this example, at least some of the frame walls 220 of the skeleton frame 218 (one of which is in...) Figure 5 (As cited in the text) are arranged spirally. For example, frame wall 220 includes a first set of frame walls 500 extending between a first end 202 and a second end 204 (of which three are in...) Figure 5 (as cited in the text) and a second set of frame walls 502 extending between the first end 202 and the second end 204 (of which three are in) Figure 5 (As cited in the text). The first set of frame walls 500 are arranged in a spiral pattern at an angle in a first direction, and the second set of frame walls 502 are arranged in a spiral pattern at an angle in a second direction and intersect with the first set of frame walls 500. The first set of frame walls 500 are equidistant from each other, and the second set of frame walls 502 are equidistant from each other. Therefore, as... Figure 5 As shown, at least a portion of window 222 is rhomboid.

[0045] In the example shown, the frame wall 220 of the skeleton frame 218 also includes a third set of frame walls 504 extending between the first end 202 and the second end 204 (of which three are in Figure 5 (Referenced herein). The third set of frame walls 504 (also referred to as vertical walls) is oriented or arranged in an axial direction (e.g., longitudinal direction, vertical direction). The third set of frame walls 504 intersects at least some of the first set of frame walls 500 and the second set of frame walls 502. The third set of frame walls 504 divides certain diamond-shaped windows into triangular windows. In the example shown, the third set of frame walls 504 are equidistant from each other around the cage 200. This arrangement of the frame walls 220 provides strength to the cage 200, which is subjected to loads during the manufacture and operation of the valve 100. In other examples, the frame walls 500, 502, and 504 may be arranged in other patterns, examples of which are disclosed in further detail herein.

[0046] Figure 6This is a cross-sectional view of an exemplary cage 200. Figure 6 As shown, the skeleton frame 218 has a first inner diameter ID1, and the mesh structure 224 has a second inner diameter ID2. The first inner diameter ID1 of the skeleton frame 218 is smaller than the second inner diameter ID2 of the mesh structure 224. This allows the skeleton frame 218 to be formed for the plug 118 ( Figure 1 It slides along the guide surface, rather than along the mesh structure 224.

[0047] like Figure 6 As shown, the skeleton frame 218 has a first outer diameter OD1, and the mesh structure 224 has a second outer diameter OD2. In this example, the first outer diameter OD1 of the skeleton frame 218 is larger than the second inner diameter OD2 of the mesh structure 224. Therefore, in this example, the skeleton frame 218 extends completely through and beyond the inner and outer sides of the mesh structure 224. In some examples, this allows the skeleton frame 218 to provide greater strength for the cage 200. In other examples, the skeleton frame 218 may extend further outward from the mesh structure 224, or it may not extend beyond the mesh structure 224, examples of which are shown herein.

[0048] This configuration of the skeleton frame 218 also reduces (e.g., minimizes) gap flow. For example, Figure 7A A plug 118 is shown in a partially open position within a cage 200. The plug 118 has an outer surface 700 and a bottom side 702. The outer surface 700 engages with and is slidable along the inner surface 226 of the skeleton frame 218. Therefore, the outer surface 700 of the plug 118 is guided along the inner surface 226 of the skeleton frame 218. Because the first inner diameter ID1 of the skeleton frame 218 is smaller than the second inner diameter ID2 of the mesh structure 224, the outer surface 700 of the plug 118 is spaced apart from the mesh structure 224 (e.g., not engaged or in contact). In the example shown, the plug 118 is in a partially open position, where the bottom side 702 separates one of the windows (labeled 222a) and its corresponding mesh structure (labeled 224a).

[0049] Figure 7B yes Figure 7A A magnified view of the annotations in the image. For example... Figure 7BAs shown, the bottom side 702 of the plug 118 is approximately halfway above the window 222a and the mesh structure 224a. As shown by fluid flow line 704, fluid can flow through the bottom portion of the mesh structure 224a and thus through the walls of the cage 200. Some fluid can also flow upwards within the mesh structure 224a, as shown by fluid flow line 705. This is sometimes referred to as upward flow. The upward flow is restricted by the frame walls 220 of the skeleton frame 218, which prevents or limits fluid flow into the next window (labeled) 222b above the bottom side 702 of the plug 118. The upward flow is blocked by the wall 220 and directed to flow radially outwards through the mesh structure 224a. Furthermore, as shown by fluid flow line 706, some fluid can flow upwards between the plug 118 and the mesh structure 224a, sometimes referred to as gap flow. However, because the plug 118 engages with the wall 220 of the skeleton frame 218, this gap flow is prevented from flowing into the next window (labeled 222b) through the skeleton frame 218. Therefore, the skeleton frame 218 reduces or restricts gap flow and upward flow.

[0050] As the plug 118 moves up or down, the shape of the window 222 allows the flow to increase or decrease continuously and gradually. If the skeleton frame 218 has horizontal walls, flat spots may exist in the flow profile when the plug 118 is opened / closed. However, utilizing... Figures 2-7B The example pattern shown depicts a continuous opening / closing of the channel as the plug 118 moves up or down. This allows for finer control of the flow rate through the cage 200.

[0051] As disclosed above, in some examples, cage 200 is constructed via additive manufacturing (e.g., 3D printing). For example, cage 200 can be constructed by a 3D printer. Thus, in some examples, cage 200 is composed of multiple layers of the same material (e.g., metal) bonded together or fused together. Cage 200 can be made of any material capable of being printed by a 3D printer. In some examples, cage 200 is made of carbon steel, 316 stainless steel, cobalt-chromium, aluminum, and / or titanium. In other examples, cage 200 can be made of other materials. In some examples, additives or other components are added to make the raw material printable via 3D printing. 3D printing is advantageous because it can be used to form small, high-density features, such as mesh structures 224. Thus, the size of opening 212 can be designed to be smaller than openings formed using other known machining techniques. In some examples, cage 200 is constructed (e.g., printed) as a single integral part or component. In other examples, cage 200 can be constructed as multiple components or segments coupled together. For example, the first end 202, the second end 204, and the wall 206 may be constructed (e.g., printed) as separate components and then coupled (e.g., welded) together to form the cage 200.

[0052] In some examples, the thickness (in the radial direction) of the frame walls 500, 502, 504 and / or the mesh structure 224 of the skeleton frame 218 can be greater or less. For example, Figure 8 This is a perspective view of cage 200. In this example, the third set of frame walls 504 (three of which are in...) Figure 8 (as cited in) from the first group of frame walls 500 and the second group of frame walls 502 (each of which is in Figure 8 (cited in) and mesh structure 224 (one of which is in) Figure 8 (As cited in the text) extends further outward (in the radial direction). In some examples, this configuration provides additional vertical support for the load.

[0053] Figure 9 It is possible Figure 1 A perspective view of another exemplary cage 900 implemented in the exemplary valve 100. The cage 900 includes a first end 902, a second end 904 opposite to the first end 902, and a wall 906 between the first end 902 and the second end 904. The wall 906 has a skeleton frame 908 between the first end 902 and the second end 904. The skeleton frame 908 defines or forms a plurality of windows 910 (one of which is in…) Figure 9 (Referenced in [reference]). In this example, window 910 is diamond-shaped. Wall 906 may include a grid structure in each window 910, similar to cage 200 disclosed above. For clarity, the grid structure is not shown in [reference]. Figure 9 As shown in the diagram. However, any example aspect of the mesh structure 224 disclosed in conjunction with cage 200 can also be applied to cage 900. Similar to cage 200, skeleton frame 908 has a smaller inner diameter than the mesh structure, which forms the space for plug 118 ( Figure 1 ) guide surface.

[0054] In the example shown, the skeleton frame 908 is similar to the skeleton frame 218 disclosed above, and has a first set of frame walls 912 arranged in a spiral pattern at an angle in a first direction (one of which is in Figure 9 (cited in the text), the second set of frame walls 914 arranged in a spiral pattern at an angle in the second direction (one of which is in Figure 9 (cited in), and a third group of walls 916 arranged in the axial direction (one of which is in) Figure 9 (Referenced in [the original text]). Similar to skeleton frame 218, Figure 8 The skeleton frame 908 provides a guiding surface for the plug 118, provides strength for the cage 900, and reduces gap flow. However, in this example, the frame walls 912, 914, 916 are spaced apart from and / or angled from the frame walls of the skeleton frame 218. For example, in this example, the third set of walls 916 is spaced apart by one (or two half-windows 910) of the windows 910.

[0055] In some examples, the skeleton frame may not include vertical (axial) walls. For example, Figure 10 This is an internal view of an exemplary cage 1000 having a skeleton frame 1002 but no axial (vertical) walls. Similar to the skeleton frame 908, the skeleton frame 1002 has a first set of walls 1004 and a second set of walls 1006 forming a rhomboid window 1008. However, the skeleton frame 1002 does not include vertical walls. Figure 10 As shown, the cage 1000 includes a mesh structure 1010 in each window 1008. The mesh structure 1010 forms or defines openings for fluid flow through the cage 1000.

[0056] In some examples, the skeleton frame may not extend beyond the exterior of the mesh structure. For example, Figure 11 The outer side 1100 of cage 1000 is shown. In this example, the skeleton frame 1002 does not extend through the entire mesh structure 1010. Therefore, the mesh structure 1010 forms the outer side 1100 of the cage.

[0057] Figure 12 A portion of another exemplary cage 1200 that can be implemented in valve 100 is shown. Cage 1200 includes a first end 1202, a second end 1204, and a wall 1206 between the first end 1202 and the second end 1204. Wall 1206 includes a skeleton frame 1208 that forms or defines a window 1212. In this example, skeleton frame 1208 has a first set of walls 1210 arranged in a polygonal configuration (one of which is in…). Figure 12 (Referenced in [reference]). Specifically, in this example, the first set of walls 1210 is arranged in a hexagonal configuration. Therefore, at least a portion of the window 1212 is polygonal, i.e., hexagonal. In other examples, the first set of frame walls 1210 may be configured to form other polygonal windows. In the example shown, the skeleton frame 1208 also includes a second set of walls 1214 extending in an axial direction (e.g., longitudinal or vertical) and intersecting with some of the walls in the first set of walls 1210 (one of which is in [reference]). Figure 12 (This is cited in the original text). However, in other examples, the skeleton frame 1208 may not include the second set of frame walls 1214.

[0058] Wall 1206 may include a mesh structure in each window 1212, similar to the cage 200 disclosed above. For clarity, the mesh structure is not shown in the diagram. Figure 12 As shown in the diagram. However, any example aspects of the mesh structure 224 disclosed in conjunction with cage 200 can also be applied to cage 1200. Similar to cage 200, the skeleton frame 1208 has a smaller inner diameter than the mesh structure, which forms the space for plug 118 ( Figure 1 ) guide surface. Figure 12 The skeleton frame 1208 also provides strength to the cage 1200 and reduces gap flow.

[0059] Figure 13 A portion of another exemplary cage 1300 that can be implemented in valve 100 is shown. Cage 1300 includes a first end 1302, a second end 1304, and a wall 1306 between the first end 1302 and the second end 1304. Wall 1306 includes a skeleton frame 1308. In this example, the skeleton frame 1308 has a first set of walls 1310 arranged in a polygonal configuration (one of which is in…). Figure 13 (Referenced in [reference]). In this example, frame walls 1310 are arranged to form a plurality of windows 1312 having polygonal shapes (such as triangles and squares). In the example shown, the skeleton frame 1308 also includes a second set of walls 1314 extending in an axial direction (e.g., longitudinal or vertical) and intersecting with some of the walls in the first set of walls 1310 (one of which is in [reference]). Figure 13 (Referenced in [reference]). Wall 1306 may include a mesh structure in each window 1312, similar to cage 200 disclosed above. For clarity, the mesh structure is not shown in [reference]. Figure 13 As shown in the diagram. However, any example aspects of the mesh structure 224 disclosed in conjunction with cage 200 can also be applied to cage 1300. Similar to cage 200, the skeleton frame 1308 has a smaller inner diameter than the mesh structure, which forms the space for plug 118 ( Figure 1 The guide surface of the frame wall 1310. In this example, the arrangement or pattern of the frame wall 1310 provides relatively high strength, which may be advantageous in higher-pressure valves with higher clamping forces. The exemplary skeleton frame 1308 also reduces or restricts gap flow.

[0060] As disclosed herein, the exemplary cage can be printed or formed via an additive manufacturing machine (commonly referred to as a 3D printer). Figure 14 An exemplary powder bed fusion machine 1400 is shown, which is a type of AM machine or 3D printer that can be used to print or form any exemplary cage. Although the powder bed fusion machine 1400 is described in conjunction with the printing cage 200, it can be similarly implemented to print any of the exemplary cages 900, 1000, 1200, 1300 having other skeleton frames and / or mesh structures disclosed herein.

[0061] In the example shown, the powder bed fusion machine 1400 includes a build platform 1402 that can be moved up and down via a platform motor 1404. To create one or more objects, such as cage 200, a substrate 1406 is placed on the build platform 1402. The substrate 1406 can be, for example, a sheet of metal (such as stainless steel). A roller 1408 then spreads a thin layer (e.g., 40 micrometers) of powder material 1410 from a reservoir 1412 (e.g., a hopper) onto the top of the substrate 1406 and the build platform 1402. The powder material 1410 can be any metal (e.g., stainless steel) and / or a polymer-based material. A laser 1414 then applies energy (in the shape of a 3D flame arrester cross-section) to the layer of powder material 1410, which sinters, fuses, and / or otherwise hardens the powder material 1410 to form layers of cage 200. In this example, the first layer of cage 200 is welded or sintered to the substrate 1406. Next, the construction platform 1402 is moved downwards slightly (e.g., 0.1 mm) via the platform motor 1404, and the roller 1408 spreads another layer of powder material 1410 onto the construction platform 1402 and the first hardened layer(s). Then, the laser 1414 applies energy to the powder material 1410 to harden the material onto the previous layer(s). This process is repeated to build the cage 200 layer by layer. Thus, the cage 200 can be constructed from multiple layers of the same material (e.g., stainless steel) bonded together. In this example, the cage 200 is constructed vertically starting from the second end 204.

[0062] Other types of powder bed fusion AM processes can be accomplished using various techniques, such as direct metal laser sintering, electron beam melting, selective thermal sintering, selective laser melting, and selective laser sintering. Powder bed fusion methods use lasers or electron beams to melt and fuse material powders together. While some exemplary cages disclosed herein are described as being constructed using powder bed fusion AM machines, any exemplary cage disclosed herein can be constructed using any other type of AM process or machine, such as VAT photopolymerization, material jetting, binder jetting, material extrusion, sheet lamination, and / or directional energy deposition.

[0063] In some examples, after the cage 200 is formed, the interior of the cage 200 is machined to smooth the inner surface 226 of the skeleton frame 218. For example, a boring bar, a flexible honing tool, a milling machine, and / or any other tool or machine can be used to smooth the inner surface 226 of the skeleton frame 218.

[0064] Figure 15 This is a flowchart illustrating an exemplary method 1500 for manufacturing an exemplary cage. The exemplary method 1500 is described in conjunction with an example cage 200. However, it should be understood that the exemplary method 1500 can be similarly performed in conjunction with any other cage disclosed herein.

[0065] At box 1502, exemplary method 1500 includes constructing a cage via an additive manufacturing process. For example, the cage 200 may be constructed via a powder bed fusion process (e.g., printing), such as bonding. Figure 14 The powder bed fusion machine 1400 is shown. In other examples, the cage 200 may be constructed via other types of additive manufacturing processes (e.g., printing), such as stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), multi-jet molding (MJM), VAT photopolymerization, material jetting, binder jetting, material extrusion, sheet lamination, and / or directional energy deposition. In some examples, the cage 200 is constructed (e.g., printed) vertically layer by layer from the second end 204 to the first end 202. In some examples, the cage 200 is constructed using stainless steel. In some examples, multiple cages 200 may be configured side-by-side and constructed simultaneously on the substrate 1406.

[0066] In some examples, the cage is constructed (e.g., printed) on a substrate (such as substrate 1406). Therefore, at box 1504, exemplary method 1500 includes removing the cage 200 from substrate 1406. For example, the cage 200 may be removed from substrate 1406 via a cutting tool or machine. In some examples, the cage 200 is cut from substrate 1406 along a cutting plane between the second end 204 and substrate 1406.

[0067] At box 1506, exemplary method 1500 includes machining the inner surface 226 of the skeleton frame 218 to create a smooth guide surface for the plug 118. The inner surface 226 can be machined using any known tools or machines.

[0068] "Comprising" and "including" (and all their forms and tenses) are used herein as open-ended terms. Therefore, whenever a claim uses any form of "comprising" or "including" (e.g., including, comprising, containing, having, etc.) as a preamble or within any kind of claim statement, it should be understood that additional elements, terms, etc., may be present without falling outside the scope of the corresponding claim or statement. As used herein, when the phrase "at least" is used as a transitional term, for example, in the preamble of a claim, it is open-ended in the same way as the terms "comprising" and "including" are open-ended. When used, for example, in the form of A, B, and / or C, the term "and / or" refers to any combination or subset of A, B, C, such as (1) only A, (2) only B, (3) only C, (4) A and B, (5) A and C, (6) B and C, or (7) A and B and C. As used herein in the context of describing structures, components, items, objects, and / or things, the phrase "at least one of A and B" is intended to refer to an implementation that includes (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects, and / or things, the phrase "at least one of A or B" is intended to refer to an implementation that includes (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. As used herein in the context of describing the performance or execution of processes, instructions, actions, activities, and / or steps, the phrase "at least one of A and B" is intended to refer to an implementation that includes (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein in the context of describing the implementation or execution of processes, instructions, actions, activities and / or steps, the phrase “at least one of A or B” is intended to refer to an implementation that includes (1) at least one A, (2) at least one B, or (3) at least one A and at least one B.

[0069] As used herein, singular references (e.g., "a," "an," "first," "second," etc.) do not exclude plural. As used herein, the term "a" or "an" refers to one or more of the same object. The terms "a" (or "an"), "one or more," and "at least one" are used interchangeably herein. Furthermore, although listed separately, multiple means, elements, or method actions can be implemented by, for example, the same entity or object. Additionally, although individual features may be included in different examples or claims, these features may be combined, and inclusion in different examples or claims does not imply that the combination of features is impractical and / or disadvantageous.

[0070] Based on the foregoing, it should be understood that the exemplary methods, apparatus, and articles of manufacture improve upon valve cages with a mesh structure. The exemplary cages disclosed herein include a skeleton frame that provides a guiding surface for the plug. Therefore, the plug does not engage with or contact the mesh structure. The skeleton frame also provides strength to the cage, which reduces the load on the cage during valve manufacturing, assembly, and / or operation. Furthermore, the exemplary skeleton frame disclosed herein reduces interstitial flow and upflow, which allows for better control of the flow rate through the cage. The exemplary cages disclosed herein can be used with compressible or incompressible fluids.

[0071] The examples and combinations of examples disclosed in this article include the following:

[0072] Example 1 is a cage for a valve, the cage comprising: a first end; a second end opposite to the first end; and a wall between the first end and the second end. The wall comprises: a skeleton frame having a plurality of frame walls extending between the first and second end portions, the skeleton frame defining a plurality of windows; and a grid structure within the windows.

[0073] Example 2 includes the cage of Example 1, wherein the first inner diameter of the skeleton frame is smaller than the second inner diameter of the mesh structure.

[0074] Example 3 includes the cage of Example 1 or 2, wherein the first outer diameter of the skeleton frame is greater than the second outer diameter of the mesh structure.

[0075] Example 4 includes a cage from any of Examples 1-3, wherein the cage comprises multiple layers of the same material bonded together.

[0076] Example 5 includes a cage from any of Examples 1-4, wherein the cage comprises stainless steel.

[0077] Example 6 includes a cage from any of Examples 1-5, wherein the mesh structure is a triple periodic mesh structure.

[0078] Example 7 includes a cage of any one of Examples 1-6, wherein the frame walls comprise a first set of frame walls arranged in a spiral pattern at an angle in a first direction and a second set of frame walls arranged in a spiral pattern at an angle in a second direction and intersecting with the first set of frame walls.

[0079] Example 8 includes the cage of Example 7, wherein at least a portion of the window is rhomboid.

[0080] Example 9 includes the cage of Example 7 or 8, wherein the frame walls include a third set of frame walls arranged axially and intersecting at least some of the frame walls in the first set of frame walls and the second set of frame walls.

[0081] Example 10 includes a cage of any of Examples 1-9, wherein at least a portion of the window is hexagonal.

[0082] Example 11 includes a cage of any of Examples 1-10, wherein at least a portion of the window is polygonal.

[0083] Example 12 is a valve comprising: a valve body defining a fluid passage between an inlet and an outlet; a plug; and a cage in the fluid passage, the plug disposed within the cage, the plug being movable within the cage to control fluid flow through the fluid passage. The cage includes: a first end; a second end; and a wall between the first end and the second end, the wall comprising a mesh structure and a skeleton frame having a plurality of frame walls extending into the mesh structure, the inner diameter of the skeleton frame being smaller than the inner diameter of the mesh structure.

[0084] Example 13 includes the valve of Example 12, wherein the outer surface of the plug is guided along the inner surface of the skeleton frame.

[0085] Example 14 includes the valve of Example 13, wherein the outer surface of the plug is spaced apart from the mesh structure.

[0086] Example 15 includes the valve of Example 13 or 14, wherein the outer diameter of the mesh structure is larger than the outer diameter of the skeleton frame.

[0087] Example 16 includes a valve of any of Examples 12-15, wherein the frame wall comprises a first set of frame walls arranged in an angled spiral pattern in a first direction and a second set of frame walls arranged in an angled spiral pattern in a second direction and intersecting the first set of frame walls.

[0088] Example 17 includes a valve of any of Examples 12-16, wherein the frame wall defines a plurality of windows, wherein at least a portion of the windows is rhomboid.

[0089] Example 18 includes a valve of any of Examples 12-17, wherein the frame wall defines a plurality of windows, wherein at least a portion of the windows is polygonal.

[0090] Example 19 is a method comprising: constructing a cage for a valve via an additive manufacturing process, the valve comprising: a first end; a second end opposite to the first end; and a wall between the first end and the second end, the wall comprising a skeleton frame extending between the first end and the second end and defining a plurality of windows, the wall comprising a grid structure in the windows.

[0091] Example 20 includes the method of Example 19, and further includes machining the inner surface of the skeleton frame to generate a smooth guide surface for the plug of the valve.

[0092] The appended claims are hereby incorporated by reference into this specific embodiment. Although certain example systems, methods, apparatuses, and articles of manufacture have been disclosed herein, the scope of this patent is not limited thereto. Rather, this patent covers all systems, methods, apparatuses, and articles of manufacture that fall fully within the scope of the claims of this patent.

Claims

1. A cage for a valve, the cage comprising: First end; The second end opposite to the first end; as well as The wall between the first end and the second end includes: A skeleton frame having a plurality of frame walls extending between a first end and a second end, the skeleton frame defining a plurality of windows; as well as The grid structure in the window.

2. The cage according to claim 1, wherein, The first inner diameter of the skeleton frame is smaller than the second inner diameter of the mesh structure.

3. The cage according to claim 1, wherein, The first outer diameter of the skeleton frame is larger than the second outer diameter of the mesh structure.

4. The cage according to claim 1, wherein, The cage is composed of multiple layers of the same material bonded together.

5. The cage according to claim 4, wherein, The cage is made of stainless steel.

6. The cage according to claim 1, wherein, The grid structure is a triple periodic grid structure.

7. The cage according to claim 1, wherein, The frame wall includes a first set of frame walls arranged in a spiral pattern at an angle in a first direction and a second set of frame walls arranged in a spiral pattern at an angle in a second direction and intersecting with the first set of frame walls.

8. The cage according to claim 7, wherein, At least a portion of the window is diamond-shaped.

9. The cage according to claim 7, wherein, The frame wall includes a third set of frame walls, which are arranged axially and intersect with at least some of the first set of frame walls and the second set of frame walls.

10. The cage according to claim 1, wherein, At least a portion of the window is hexagonal.

11. The cage according to claim 1, wherein, At least a portion of the window is polygonal.

12. A valve comprising: Valve body, which defines a fluid passage between an inlet and an outlet; Block; as well as A cage in the fluid channel, a plug disposed in the cage, the plug being movable within the cage to control the fluid flow through the fluid channel, the cage comprising: First end; The second end; and The wall between the first end and the second end includes a mesh structure and a skeleton frame, the skeleton frame having a plurality of frame walls extending into the mesh structure, the inner diameter of the skeleton frame being smaller than the inner diameter of the mesh structure.

13. The valve according to claim 12, wherein, The outer surface of the plug is guided along the inner surface of the skeleton frame.

14. The valve according to claim 13, wherein, The outer surface of the plug is spaced apart from the mesh structure.

15. The valve according to claim 13, wherein, The outer diameter of the mesh structure is larger than the outer diameter of the skeleton frame.

16. The valve according to claim 12, characterized in that, The frame wall includes a first set of frame walls arranged in a spiral pattern at an angle in a first direction and a second set of frame walls arranged in a spiral pattern at an angle in a second direction and intersecting with the first set of frame walls.

17. The valve according to claim 12, wherein, The frame wall defines a plurality of windows, wherein at least a portion of the windows is diamond-shaped.

18. The valve according to claim 12, wherein, The frame wall defines a plurality of windows, wherein at least a portion of the windows is polygonal.

19. A method comprising: A cage for a valve is constructed via an additive manufacturing process, the cage comprising: First end; The second end opposite to the first end; and A wall between the first end and the second end, the wall comprising a skeleton frame extending between the first end and the second end and defining a plurality of windows, the wall comprising a grid structure in the windows.

20. The method of claim 19, further comprising machining the inner surface of the skeleton frame to generate a smooth guide surface for the plug of the valve.

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