Method of manufacturing a fluid reduced pressure apparatus

Abstract

A method of custom manufacturing a fluid decompression apparatus for a process control valve. The method includes creating a fluid reduced pressure device using an additive manufacturing technique that generally includes forming a body and forming a plurality of flow paths in the body. The body has an inner wall and an outer wall spaced radially outward from the inner wall. A flow path is formed in the body between the inner wall and the outer wall of the body. Each flow path includes an inlet aperture, an outlet aperture, and an intermediate portion extending between the inlet aperture and the outlet aperture. At least a portion of the intermediate portion extends in a substantially vertical direction substantially parallel to the longitudinal axis such that the flow path can utilize previously unused space in the apparatus.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 201810516274.4, filed on May 25, 2018, entitled “Method for Manufacturing Fluid Pressure Reduction Device”. Technical Field

[0002] This disclosure relates generally to fluid pressure reducing devices, and more specifically to methods for manufacturing devices that more effectively reduce fluid pressure in process control systems. Background Technology

[0003] In process control systems, such as distributed or scalable systems commonly found in chemical, petroleum, power generation, or other industrial processes, there is often a need to reduce fluid pressure. However, pressure drops typically lead to an undesirable increase in noise and / or vibration levels. Therefore, process control systems often employ flow reduction devices designed to reduce fluid pressure in a manner that does not result in increased noise and / or vibration levels.

[0004] U.S. Patent No. 6,935,370 (“370 Patent”) illustrates several different examples of fluid pressure reducing devices, each taking the form of multiple stacked discs that, when used in a fluid flow control valve, reduce the pressure of the fluid flowing through it. One example (as shown in Figure 5 of the '370 Patent) features multiple stacked annular discs 100 rotating relative to each other to create flow paths 62, each providing multi-stage pressure reduction. Each disc 60 of the stack 100 has a laser-cut profile that defines a horizontal helical flow path 62 extending from an inlet portion 68, through an intermediate portion 70 formed by a series of flat leg portions and including limiting portions 74, 76, and extending to an outlet portion 72 having a larger cross-sectional area than the inlet portion 68. Another example illustrated in Figure 8 of the '370 Patent features an annular disc 130 having phase exchange fluid flow paths 136, 138 such that the fluid flowing therein collides, thereby releasing energy and reducing fluid pressure. Summary of the Invention

[0005] According to a first exemplary aspect of the present invention, a fluid pressure reducing device for a fluid flow control apparatus. The fluid pressure reducing device includes an integrated body and a plurality of flow paths. The integrated body has an inner wall and an outer wall radially outwardly spaced from the inner wall, the integrated body extending along a longitudinal axis. The flow paths are defined between the inner wall and the outer wall of the integrated body. Each flow path includes an inlet orifice, an outlet orifice, and an intermediate portion extending between the inlet orifice and the outlet orifice. At least a portion of the intermediate portion extends in a direction substantially parallel to the longitudinal axis.

[0006] According to a second exemplary aspect of the present invention, a fluid pressure reducing device for a fluid flow control apparatus. The fluid pressure reducing device includes an integrated body and a plurality of flow paths. The integrated body includes a central opening and a peripheral portion surrounding the central opening, the peripheral portion having a top end and a bottom end opposite the top end. The flow paths are defined in the peripheral portion of the integrated body, each flow path including an inlet orifice, an outlet orifice, and a middle portion connecting the inlet orifice and the outlet orifice. The middle portion extends between a position near the bottom end of the body and a position near the top end of the body.

[0007] According to a third exemplary aspect of the invention, a method of manufacturing is provided. The method includes creating a fluid depressurization device using additive manufacturing techniques. The creation includes: forming a body having an inner wall and an outer wall radially outwardly spaced from the inner wall, the body extending along a longitudinal axis; and forming a plurality of flow paths in the body between the inner wall and the outer wall, each flow path including an inlet orifice, an outlet orifice, and an intermediate portion extending between the inlet orifice and the outlet orifice, wherein at least a portion of the intermediate portion extends in a direction substantially parallel to the longitudinal axis.

[0008] Furthermore, according to any one or more of the foregoing first, second and third exemplary aspects, the fluid pressure reducing device and / or manufacturing method may include any one or more of the following further preferred forms.

[0009] In a preferred embodiment, the basic portion of the intermediate section extends in the stated direction.

[0010] In another preferred embodiment, the integrated body has a length defined between the top and bottom ends of the integrated body, and at least a portion of the middle portion extending in the vertical direction travels at least a majority of the length of the integrated body.

[0011] In another preferred embodiment, the inlet and outlet holes are oriented along an axis substantially perpendicular to the longitudinal axis.

[0012] In another preferred embodiment, a plurality of pressure limiting portions are defined in the intermediate portion.

[0013] In another preferred embodiment, the intermediate portion includes a first vertical portion connected to the inlet portion and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet portion and substantially parallel to the longitudinal axis, and a curved portion connecting the first vertical portion and the second vertical portion.

[0014] In another preferred embodiment, the inlet and outlet holes are positioned near the bottom of the integrated body, and the curved portion of the middle section is positioned near the top of the integrated body.

[0015] In another preferred embodiment, the first and second flow paths of the plurality of flow paths share a common intermediate section.

[0016] In another preferred embodiment, the intermediate portion includes a first vertical portion connected to the inlet portion and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet portion and substantially parallel to the longitudinal axis, and a plurality of intermediate holes connecting the first vertical portion and the second vertical portion and substantially perpendicular to the longitudinal axis.

[0017] In another preferred embodiment, the inlet orifice has a first diameter, the intermediate orifices of the intermediate portion each have a second diameter larger than the first diameter, and the outlet orifice has a third diameter larger than the second diameter.

[0018] In another preferred embodiment, the periphery is defined by an inner wall and an outer wall that is radially spaced outward from the inner wall, and the flow path is defined between the inner wall and the outer wall.

[0019] In another preferred embodiment, the integrated body extends along a longitudinal axis, and wherein the intermediate portion includes a first vertical portion connected to the inlet hole and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet portion and substantially parallel to the longitudinal axis, and a curved portion connecting the first vertical portion and the second vertical portion.

[0020] In another preferred embodiment, the inlet and outlet holes are positioned near the bottom end of the integrated body, and the curved portion of the middle section is positioned near the top end of the integrated body.

[0021] In another preferred embodiment, the integrated body extends along a longitudinal axis, and wherein the intermediate portion includes a first vertical portion connected to the inlet hole and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet hole and substantially parallel to the longitudinal axis, and a plurality of intermediate holes connecting the first vertical portion and the second vertical portion and substantially perpendicular to the longitudinal axis.

[0022] In another preferred embodiment, the inlet orifice has a first diameter, each of the intermediate orifices has a second diameter larger than the first diameter, and the outlet orifice has a third diameter larger than the second diameter.

[0023] In another preferred embodiment, the additive manufacturing technology includes 3D printing.

[0024] In another preferred embodiment, the action of forming the plurality of flow paths in the body includes forming the intermediate portion to include a first vertical portion connected to the inlet portion and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet portion and substantially parallel to the longitudinal axis, and a curved portion connecting the first vertical portion and the second vertical portion.

[0025] In another preferred embodiment, the action of forming the plurality of flow paths in the body includes forming intermediate portions to include a first vertical portion connected to the inlet orifice and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet orifice and substantially parallel to the longitudinal axis, and a plurality of intermediate orifices connecting the first vertical portion and the second vertical portion and substantially perpendicular to the longitudinal axis. Attached Figure Description

[0026] The features of the invention, which are considered novel, are specifically set forth in the appended claims. The invention can be best understood by referring to the following description taken in conjunction with the accompanying drawings, wherein similar reference numerals denote similar elements in several drawings, wherein: Figure 1 This is a schematic diagram illustrating an example of a process or method for manufacturing a fluid pressure reducing device based on the teachings of this disclosure; Figure 2A It is based on Figure 1 A perspective view of a first example of a fluid pressure reducing device manufactured using the process; Figure 2B yes Figure 2A A cross-sectional view of a fluid pressure reducing device; Figure 2C yes Figure 2A Another cross-sectional view of the fluid pressure reducing device; Figure 2D yes Figure 2A The front plan view of the fluid pressure reducing device shows multiple flow paths, but the rest of the device has been removed for clarity. Figure 2E yes Figure 2A A top plan view of the fluid pressure reducing device, showing multiple flow paths, but the rest of the device has been removed for clarity; Figure 3A It is based on Figure 1 A perspective view of a second example of a fluid decompression device manufactured using the process; Figure 3B yes Figure 3A A cross-sectional view of a fluid pressure reducing device; Figure 3C yes Figure 3A Another cross-sectional view of the fluid pressure reducing device; Figure 3D It is along Figure 3C A 3D-3D cross-sectional view of the line in the image; and Figure 4 It is based on Figure 1 A cross-sectional view of a third example of a fluid depressurization device manufactured using the process. Detailed Implementation

[0027] This disclosure generally relates to methods for manufacturing devices that reduce fluid pressure more effectively than conventional fluid pressure reducing devices (such as the stacked disk 100 described above), and are simultaneously easier and less costly to manufacture than such conventional fluid pressure reducing devices. The methods described herein utilize cutting-edge manufacturing techniques (e.g., additive manufacturing) to facilitate the custom manufacturing of fluid pressure reducing devices, allowing any number of different flow paths to be developed and integrated into a unitary body or a single body, depending on the given application. Thus, fluid pressure reducing devices can, for example, include complex flow paths that substantially utilize the entire contour of the device (compared to conventional fluid pressure reducing devices, which typically have a large amount of unused space or dead zones), thereby maximizing (or at least enhancing) the flow path length and, consequently, maximizing (or at least enhancing) the pressure reducing capacity of the device.

[0028] Figure 1 This is a diagram illustrating an example of the method or process 100 taught according to the present invention. Figure 1 The method or process 100 schematically depicted is a method or process for custom manufacturing a fluid pressure reducing device, such as a valve internal component (e.g., a valve cage). Similar to the conventional fluid pressure reducing devices described above (e.g., a stack of discs 100), the fluid pressure reducing device manufactured according to method or process 100 is configured to reduce the pressure of the fluid flowing through it, but as mentioned above, it is easier and less expensive to manufacture than conventional fluid pressure reducing devices, and at the same time, it is just as effective as conventional fluid pressure reducing devices, even if not more effective.

[0029] More specifically, method 100 includes action 104 of creating a custom fluid decompression device using additive manufacturing techniques based on a given application. Additive manufacturing techniques can be any additive manufacturing technique or process that constructs a three-dimensional object by adding continuous layers of material onto a material. Additive manufacturing techniques can be performed by any suitable machine or combination of machines. Additive manufacturing techniques typically involve or utilize computers, 3D modeling software (e.g., computer-aided design or CAD software), machine equipment, and layered materials. Once a CAD model is generated, the machine equipment can read data from the CAD file and stack or add continuous layers of liquids, powders, or sheets (e.g.) in a layer-by-layer manner to create a three-dimensional object. Additive manufacturing techniques can include any of several techniques or processes, such as, for example, stereolithography (“SLA”), fused deposition modeling (“FDM”), multi-jet modeling (“MJM”), selective laser sintering (“SLS”), electron beam additive manufacturing, and arc welding additive manufacturing. In some embodiments, the additive manufacturing process can include a directed energy laser deposition (DEL) process. Such a DEL process can be performed by a multi-axis computer numerical control (“CNC”) lathe with DEL capabilities.

[0030] Action 104 in creating a custom fluid pressure reducing device includes forming an integral body or a single body (action 108) and forming multiple flow paths within the integral body or single body (action 112). The integral body can be made of one or more suitable materials, such as, for example, stainless steel, aluminum, various alloys, and, due to its customizability, can be any number of different shapes and / or sizes. As an example, the integral body can take the form of a hollow cylinder defined by an inner wall and an outer wall radially spaced outward from the inner wall. The flow paths formed in the body are typically configured to reduce the pressure of the fluid flowing through it. As described above, custom manufacturing of fluid pressure reducing devices using additive manufacturing techniques allows flow paths to be formed based on the desired application. In other words, the flow paths are customizable. Due to this customizability, the flow paths can be unique and complex (rather than simple), having any number of different lengths, any number of different sizes and / or cross-sectional shapes, and / or can be arranged in any number of different patterns. As a result, one or more flow paths may be formed to include or define multiple different pressure levels (e.g., a first pressure level and a second pressure level in which the pressure is less than that in the first pressure level), one or more flow paths may be partially or even substantially non-horizontal (i.e., include a vertical component), one or more flow paths may vary in shape and / or size as fluid passes through them, one or more flow paths may differ from one or more other flow paths, flow paths may be offset or deviated from each other (horizontally or vertically) through the integrated body, one or more flow paths may extend between a position near the top of the integrated body and a position near the bottom of the integrated body (e.g., moving or extending a substantial portion of the length of the integrated body), such that the entire outline of the actual device is utilized, or a combination of these.

[0031] It should be understood that action 104 (and actions 108, 112) can be performed any number of different times. Action 104 can be performed multiple times, for example, to create multiple fluid pressure reducing devices for a single process control valve, wherein each fluid pressure reducing device is created for a specific application. Alternatively or additionally, action 104 can be performed multiple times to create fluid pressure reducing devices for multiple similar or different process control valves.

[0032] Figures 2A-2EA first example of a fluid pressure reducing device 200 custom-manufactured using this method or process 100 is illustrated. The fluid pressure reducing device 200 in this example takes the form of a valve cage, which can be disposed within the valve body of a process control valve (e.g., a sliding rod valve). The fluid pressure reducing device 200 has a single body or an integrated body 204 and multiple flow paths 208 formed or defined within the integrated body 204 to reduce the pressure of the fluid flowing through the body 204. As will be discussed in more detail below, the flow paths 208 are formed in the integrated body 204 in a manner that practically utilizes the entire outline of the device 200, thereby maximizing (or at least increasing) the length of the flow paths 208, and consequently maximizing (or at least enhancing) the pressure reducing capacity of the device 200.

[0033] like Figure 2A-2C As illustrated, the body 204 has a central opening 212 and a generally cylindrical peripheral portion 216 surrounding the central opening 212. The central opening 212 extends along a central longitudinal axis 218 and is sized to receive a valve plug of a process control valve, which is movably disposed therein to control the flow of fluid through the process control valve. The generally cylindrical peripheral portion 216 is defined by an inner wall 220 (which in turn defines the central opening 212) and an outer wall 224 radially outwardly spaced from the inner wall 220.

[0034] As shown in the figure, flow paths 208 are formed in the peripheral portion 216 between the inner wall 220 and the outer wall 224, and are arranged circumferentially around the central opening 212. Each flow path 208 has a circular cross-section and includes an inlet hole 236, an outlet hole 240, and a middle portion 244 extending between the inlet hole 236 and the outlet hole 240.

[0035] Inlet orifices 236 are formed in and through the inner wall 220 (and thus in direct fluid communication with the central opening 212), each orifice oriented along a first axis (e.g., first axis 226) substantially perpendicular to (e.g., precisely perpendicular to) the longitudinal axis 218. The inlet orifices 236 of the flow path 208 are arranged in multiple rows 228, wherein alternating rows 228 of inlet orifices 236 are offset from or offset from each other. For example, the inlet orifices 236 in row 228A are offset from or offset from the inlet orifices 236 in row 228B adjacent to row 228A. Although the inlet orifices 236 do not necessarily have to be offset in this way (or completely), offsetting the inlet orifices 236 in this way helps to achieve balanced fluid flow throughout the fluid pressure reducing device 200.

[0036] Outlet holes 240 are formed in and through the outer wall 224, each outlet hole oriented along a second axis (e.g., second axis 246), which is substantially coaxial with the first axis (e.g., first axis 226), if not precisely coaxial (and therefore substantially perpendicular to the longitudinal axis 218, if not precisely perpendicular). Like inlet holes 236, outlet holes 240 are arranged in multiple rows 247, the alternating rows 247 of outlet holes 240 being offset or offset from each other in a manner similar to the alternating rows 228 of inlet holes 236. However, in other examples, outlet holes 240 may be arranged differently (e.g., different from each other, different from inlet holes 236) or not offset or offset at all.

[0037] In this example, the middle portion 244 is U-shaped and extends from the bottom end 248 near the body 204 (where portions 244 at the bottom end 248 are connected to the inlet holes 236), upwards within the peripheral portion 216 toward the top end 252 of the body 204, and downwards back to the position near the bottom end 248 (where portions 244 at the bottom end 248 are connected to the outlet holes 240). In other words, the middle portion 244 of each flow path 208 sweeps or travels upwards and downwards back, i.e., 180 degrees. Therefore, as illustrated, each intermediate portion 244 has a first vertical portion 256 (e.g., a vertical chamber connected to the corresponding inlet hole 236 and substantially parallel to the longitudinal axis 218), a second vertical portion 260 (e.g., a vertical chamber connected to the corresponding outlet hole 240 and substantially parallel to the longitudinal axis 218), and a curved portion 264 (e.g., a curved chamber located above the inlet hole 236 and the outlet hole 240 that connects the first vertical portion 256 and the second vertical portion 260 to each other).

[0038] In this arrangement, the basic portion of the intermediate portion 244 of each flow path 208 is oriented in a substantially vertical direction (i.e., substantially parallel to the longitudinal axis 218), even if not precisely vertical (i.e., precisely perpendicular to the longitudinal axis 218). And because the intermediate portion 244 comprises the basic portion of each flow path 208 in this example, the basic portion of each flow path 208 is oriented in a substantially vertical direction (or precisely vertical direction). However, this is not the case in other examples. In some examples, a larger portion of the intermediate portion 244 may be oriented in a non-vertical direction, for example, at an angle relative to the longitudinal axis 218. Alternatively or additionally, the inlet orifice 236 and the outlet orifice 240 may comprise a larger portion of each flow path 208, such that the intermediate portion 244 comprises a large portion, but not a substantial portion, of each flow path 208.

[0039] In this example, each intermediate section 244 also includes a plurality of pressure limiting sections 268, each pressure limiting section 268 being formed by narrowing the intermediate section 244 to generate additional pressure reduction in stages. In the illustrated example, each intermediate section 244 includes four pressure limiting sections 268 spaced apart from each other along the entire length of the intermediate section 244. In other examples, more or fewer pressure limiting sections 268 may be used (to generate more or less pressure reduction).

[0040] It should be understood that the intermediate portions 244 of different flow paths 208 (more specifically, the curved portions 264 of those portions 244) will extend or travel upward to different points within the peripheral portion 216. In other words, some intermediate portions 244 will be positioned closer to the top 252 of the body 204 than others. As an example, the intermediate portion 244 of flow path 208A extends to a higher position than the intermediate portion 244 of flow path 208B, i.e., closer to the top 252 of the body 204. Thus, the flow paths 208 together substantially span the entire peripheral portion 216. In other words, the flow paths 208 are formed throughout the peripheral portion 216, from the bottom 248 to the top 252 of the body 204, thereby maximizing the length of the flow paths 208 by leaving a small (if any) unused upper dead zone in the fluid pressure reducing device 200 (unlike conventional fluid pressure reducing devices).

[0041] It will also be understood that the length of one or more intermediate portions 244 may differ from that of one or more other intermediate portions 244, such that one or more flow paths 208 are longer (or shorter) than one or more other flow paths 208. This allows for a reduction in variable pressure within the pressure-reducing device 200, where a longer flow path 208 is configured to reduce fluid pressure to a greater extent than other flow paths 208. As an example, flow paths 208A and 208B, having inlet orifices 236 and outlet orifices 240 respectively formed closer to the bottom end 248 than flow paths 208C and 208D, can be formed to be longer than flow paths 208C and 208D to effectively accommodate larger pressure changes that may occur as the valve plug of the process control valve first begins to move to the open position (not shown), exposing the inlet orifices 236 of flow paths 208A and 208B. As the valve plug further opens, exposing additional flow paths 208 like flow paths 208C and 208D, shorter flow paths can be used because smaller pressure changes need to be accommodated. At the same time, these additional shorter flow paths can effectively manage any pressure differential changes.

[0042] In other examples, the inlet orifice 236 of each flow path 208 may be formed in and through the outer wall 224 (instead of the inner wall 220), and the outlet orifice 240 of each flow path 208 may be formed in and through the inner wall 220 (instead of the outer wall 224), such that fluid flows through the fluid pressure reducing device 200 in the opposite direction (from the outer diameter to the inner diameter). Furthermore, in other examples, the intermediate portion 244 of each flow path 208 may be in shape and / or size similar to... Figures 2A-2E The difference is not described in the text. As an example, the intermediate portion 244 may include one or more portions extending downward below the inlet orifice 236 and the outlet orifice 240, such that the device 200 provides a downward flow configuration (rather than an upward flow configuration). Furthermore, although the flow paths 208 in this example each have a constant diameter, in other examples, the flow paths 208 may have a variable diameter (e.g., by making the intermediate portion 244 gradual), thereby providing a recovery area for the fluid flowing through them.

[0043] When the fluid pressure reducing device 200 is in operation (within the valve body of the process control valve), and the valve plug is moved to a partially open position (exposing some inlet holes 236) or a fully open position (exposing all inlet holes 236), fluid flows from the valve body through the central opening 212 into the exposed inlet holes 236 of the flow path 208. The fluid then flows into the flow path 208 and through the intermediate portions 244. As the fluid travels upwards or sweeps (via the first vertical portion 256), it drags across or along the outer contour of each intermediate portion 244, while gravity acts on the fluid, thereby reducing its velocity. Along the way, the fluid encounters pressure limiting portions 268 in each intermediate portion 244, which respectively contribute to additional pressure reduction. Thus, the fluid pressure is reduced to a level less than its initial fluid pressure. As the fluid travels downwards or sweeps back (via the second vertical portion 260), it continues to drag along or over the outer contour of the intermediate portion 244, further reducing its velocity. The fluid encounters the pressure limiting portion 268 again along its path, which contributes to additional pressure reduction. Thus, the fluid pressure is further reduced. The depressurized fluid then flows out of the pressure reducing device 200 (and into the valve body) through the outlet port 240 of the flow path 208. In this way, the device 200 reduces the pressure of the fluid flowing through it (and thus through the process control valve). However, by employing a complex flow path 208 that essentially utilizes the entire contour of the device 200, the device 200 reduces fluid pressure more effectively than conventional fluid pressure reducing devices.

[0044] Figures 3A-3DA second example of a fluid pressure reducing device 300 custom-manufactured using this method or process 100 is illustrated. The fluid pressure reducing device 300 in this example also takes the form of a valve cage, which can be used for the valve body of a process control valve (e.g., a sliding rod valve). The fluid pressure reducing device 300 is a staged pressure reducing device having a single body or an integrated body 304 and multiple flow paths 308 formed or defined within the integrated body 304 to reduce the pressure of the fluid flowing through the body 304. Like flow path 208, flow path 308 is formed in the integrated body 304 in a manner that practically utilizes the entire outline of the device 300, thereby maximizing (or at least increasing) the length of the flow path 308, and thus maximizing (or at least enhancing) the pressure reducing capacity of the device 300.

[0045] like Figure 3A , 3B As illustrated in 3C, the body 304 has a central opening 312 and a generally cylindrical peripheral portion 316 surrounding the central opening 312. The central opening 312 extends along a central longitudinal axis 318 and is sized to receive a valve plug of a process control valve, which is movably disposed therein to control the flow of fluid through the process control valve. The generally cylindrical peripheral portion 316 is defined by an inner wall 320 (which in turn defines the central opening 312) and an outer wall 324 that is radially outwardly spaced from the inner wall 320.

[0046] like Figures 3A-3D As best illustrated, flow paths 308 are formed in a peripheral portion 316 between the inner wall 320 and the outer wall 324, and are arranged circumferentially around a central opening 312. Each flow path 308 has a variable cross-sectional shape, partially defined by an inlet orifice 336 and an outlet orifice 340.

[0047] Inlet orifices 336 are formed in and through the inner wall 320 (and thus in direct fluid communication with the central opening 312), each orifice oriented along a first axis (e.g., first axis 326) substantially perpendicular to (e.g., perpendicular to) the longitudinal axis 318. The inlet orifices 336 are arranged in a plurality of rows 328 and a plurality of columns 329, with alternating rows 328 of the inlet orifices 336 offset from or staggered from each other, and alternating columns 329 of the inlet orifices 336 offset from or staggered from each other. For example, the inlet orifices 336 in row 328A are offset from or staggered from the inlet orifices 336 in row 328B adjacent to row 328A, and the inlet orifices 336 in column 329A are offset from or staggered from the inlet orifices 336 in adjacent column 329B. As described above, offsetting the inlet orifices 336 in this manner helps to achieve balanced fluid flow throughout the fluid pressure reducing device 300, although the inlet portions 336 need not be offset in this manner (or not at all).

[0048] Outlet holes 340 are formed in and near the outer wall 324, each outlet hole oriented along a second axis (e.g., second axis 346), which is substantially parallel to the first axis 326 (and therefore substantially perpendicular to the longitudinal axis 318) but spaced apart from the first axis 326. Like the inlet holes 336, the outlet holes 340 are arranged in a plurality of rows 345 and a plurality of columns 347 (in... Figure 3D (Best visible in the middle). Although alternating column 347 is staggered or offset from each other in a similar way to alternating column 329, alternating row 345 is staggered or offset from each other in a different way than alternating row 328. (See below for details.) Figure 3B and 3C As illustrated, the alternating rows 345 of the outlet holes 340 are spaced further apart than the alternating rows 328 of the inlet holes 336. Therefore, as an example, the distance between the outlet holes 340 in row 345A and the outlet holes 340 in row 345B is greater than the distance between the inlet holes 336 in row 328A (which are associated with the outlet holes 340 in row 345A) and the inlet holes 336 in row 328B (which are associated with the outlet holes 340 in row 345B). As a result, the outlet holes 340 span a larger portion of the peripheral portion 316 of the body 304 than the inlet holes 336, and are thus positioned closer to the top 352 of the body 304, which is associated with both the outlet holes 340 and the inlet holes 336. Although this difference can vary, in the illustrated example, the portion of the peripheral portion 316 spanned by the outlet holes 340 is twice the portion of the peripheral portion 316 spanned by the inlet holes 336.

[0049] In other examples, the inlet orifice 336 of each flow path 308 may be formed in and through the outer wall 324 (instead of the inner wall 320), and the outlet orifice 340 of each flow path 308 may be formed in and through the inner wall 320 (instead of the outer wall 324), such that fluid flows through the fluid pressure reducing device 300 in the opposite direction (from the outer diameter to the inner diameter).

[0050] Each flow path 308 is further defined by an intermediate portion 344 extending between a corresponding hole in the inlet orifice 336 and a corresponding hole in the outlet orifice 340, and shared with a plurality of other associated flow paths 308. In other words, the fluid pressure reducing device 300 includes a plurality of common intermediate portions 344. In the illustrated example, each intermediate portion 344 serves as a common intermediate portion of the flow paths 308, including the inlet orifice 336 in the same column 329 of the inlet orifice 336, and further including all the outlet orifices 340 in column 347 of the outlet orifices 340 associated with the column 329 of the inlet orifice 336, respectively. As an example, intermediate portion 344A serves as a common intermediate portion of the flow paths 308, including the inlet orifice 336 in column 329A and the outlet orifice 340 in column 347A (as associated with column 329A). However, in other examples, intermediate portions 344 may serve as common intermediate portions of flow paths 308 that are associated differently.

[0051] like Figure 3B and 3C As illustrated, the intermediate portion 344 in this example is slightly V-shaped and extends from a position immediately adjacent to the bottom end 348 of the body 304 (where each portion 344 is connected to its associated inlet port 336), within the peripheral portion 316 towards and immediately adjacent to the top end 352 of the body 304, and then returns upward and downward to a position immediately adjacent to the bottom end 348 (where each portion 344 is connected to its associated outlet port 340). As illustrated, each intermediate portion 344 has a first chamber 356 connected to its associated corresponding inlet port 336, a second chamber 360 connected to its associated corresponding outlet portion 340, and a plurality of intermediate ports 364 connecting the first chamber 356 and the second chamber 360. Although not illustrated herein, each intermediate portion 344 may optionally include one or more pressure limiting portions, such as the pressure limiting portion 268 described above, for the purpose of generating additional decompression through gradation.

[0052] In this example, the first chamber 356 extends in a substantially vertical direction but is oriented at a small angle relative to the longitudinal axis 318, such that as the first chamber 356 extends upward toward the intermediate flow orifice 364, it is slightly radially outward toward the outer wall 324. In this example, the second chamber 360 also extends in a substantially vertical direction but is oriented at a small angle relative to the longitudinal axis 318, such that as the second chamber 360 extends downward away from the flow orifice 364, it is slightly radially outward toward the outer wall 324. As shown, the first chamber 356 and the second chamber 360 are abruptly transitioned, which helps to facilitate gradual decompression of the fluid as it flows through them. However, in other examples, such a gradual transition between the first chamber 356 and the second chamber 360 is not necessary.

[0053] The number of intermediate holes 364 in each intermediate section 344 preferably corresponds to the number of inlet holes 336 and outlet holes 340 associated with the corresponding intermediate section 344. Therefore, for example, as... Figure 3B and 3C As shown, when the intermediate portion 344A is associated with eight inlet holes 336 and eight outlet holes 340, the intermediate portion 344A preferably includes eight intermediate holes 364. Each intermediate hole 364 (in each intermediate portion 344) is oriented along a third axis (e.g., third axis 366), which is substantially parallel to the first and second axes (e.g., axes 326, 346), but spaced apart from them. In the illustrated example, all the intermediate holes 364 in each intermediate portion 344 are located above the inlet holes 336 and the outlet holes 340 (i.e., closer to the top end 352 of the body 304 than the inlet holes 336 and the outlet holes 340). However, in other examples, some or all of the intermediate holes 364 may be located on the same horizontal plane as or below the inlet holes 336 and / or the outlet holes 340.

[0054] Preferably, each outlet orifice 340 will have a larger diameter than each intermediate flow orifice 364, and the intermediate flow orifice 364 will have a larger diameter than each inlet orifice 336, such that the outlet orifice 340 has a maximum diameter. In one example, each outlet orifice 340 has a diameter of approximately 0.16 inches, each intermediate flow orifice 364 has a diameter of approximately 0.14 inches, and each inlet orifice has a diameter of approximately 0.12 inches. However, in other examples, the diameter of the outlet orifice 340 may be smaller than the diameter of the intermediate flow orifice 364 and / or the inlet orifice 336. Furthermore, in other examples, one or more inlet holes 336 may have a diameter different from one or more other inlet holes 336 (e.g., the inlet hole 336 closer to the bottom end 352 of the body 304 may have a larger diameter than the other inlet holes 336), one or more outlet holes 340 may have a diameter different from one or more other inlet hole outlet holes 340 (e.g., the outlet hole 340 closer to the bottom end 352 of the body 304 may have a larger diameter than the other outlet holes 340), and / or one or more intermediate holes 364 may have a diameter different from one or more other intermediate holes 364 (e.g., the intermediate hole 364 closer to the bottom end 352 of the body 304 may have a larger diameter than the other intermediate holes 364).

[0055] With each intermediate portion 344 arranged in this way, the basic portion of the intermediate portion 344 of each flow path 308 is oriented in a substantially vertical direction. And because in this example, the intermediate portion 344 includes the basic portion of each flow path 308 (although sharing a basic portion with other flow paths 308), but in this example, the basic portion of each flow path 308 is oriented in a substantially vertical direction. However, this is not the case in other examples. In some examples, a larger portion of each intermediate portion 344 may be oriented in a non-vertical direction, for example, at an angle relative to the longitudinal axis 318. Alternatively or additionally, the inlet orifice 336 and the outlet orifice 340 may include a larger portion of each flow path 308, such that the intermediate portion 344 includes a large portion, but not a substantial portion, of each flow path 308.

[0056] In addition to being essentially vertically oriented, the flow path 308 essentially spans the entire periphery 316. In other words, the flow path 308 is formed across the periphery 316 from the bottom 348 to the top 352 of the body 304, thereby maximizing the length of the flow path 308 by leaving a small amount (if any) of unused upper dead zone in the fluid pressure reducing device 300 (unlike conventional fluid pressure reducing devices).

[0057] When the fluid pressure reducing device 300 is in operation (within the valve body of the process control valve) and the valve plug is moved to the fully open position, thus exposing all inlet holes 336, fluid enters from the valve body through the central opening 312 into the inlet holes 336 of the flow path 308. The fluid then flows into and through a common intermediate section 344 shared by the flow path 308. As the fluid travels upward (via the first chamber 356), it drags across or along the outer contour of each intermediate section 344, while gravity acts on the fluid, reducing its velocity. Thus, the fluid pressure decreases to a level less than its initial fluid pressure. The first chamber 356 of the intermediate section 344 then feeds fluid into intermediate holes 364, which in turn transfer fluid to the second chamber 360. As the fluid returns downward (via the second chamber 360), it continues to drag across or along the outer contour of each intermediate section 344, further reducing its velocity. The fluid pressure is thus further reduced. The depressurized fluid then flows out of the pressure reducing device 300 (and into the valve body) via the outlet orifice 340 of the flow path 308. In this way, the device 300 reduces the pressure of the fluid flowing through it (and thus through the process control valve). However, by employing a complex flow path 308 that essentially utilizes the entire contour of the device 300, the device 300 reduces fluid pressure more effectively than conventional fluid pressure reducing devices. Furthermore, as the fluid travels through the flow path 308, additional pressure reduction beyond that seen in conventional fluid pressure reducing devices is achieved by increasing the diameter of the orifices in each flow path 308. Moreover, although the outlet orifice 340 expands to help achieve the desired pressure reduction, the fluid pressure reducing device 300 does not require a large actuator (i.e., an actuator with a long stroke) because of the positioning of the inlet orifice 336 (which does not expand in the same way as the outlet orifice 340).

[0058] It will also be understood that even when the valve plug is moved to the partially open position, the aforementioned decrease in fluid pressure occurs, thereby exposing one or more rows 328 of the inlet port 336. In this case, fluid will flow from the valve body through the central opening 312 into the exposed inlet port 336. The fluid will then travel through the pressure reducing device 300 in the manner described above, utilizing all associated intermediate ports 364 and outlet ports 340, although less than all inlet ports 336 are exposed.

[0059] Figure 4A third example of a fluid pressure reducing device 400 custom-manufactured using the method or process 100 is illustrated. The fluid pressure reducing device 400 is substantially similar to the fluid pressure reducing device 300, wherein common reference numerals are used to indicate common components. However, instead of including multiple common intermediate portions 344 (as in device 300), device 400 includes a single common intermediate portion 444 arranged circumferentially around the entire central opening 312 of body 304. In this example, the single common intermediate portion 444 is a curved space or region defined or formed between the inner walls 320, 324 of body 304 (and thus the inlet or outlet orifice 336 and 340, respectively). More specifically, the curved space or region is defined between a first intermediate wall 480 and a second intermediate wall 484, the first intermediate wall 480 being positioned radially outward adjacent to the inner wall 320 and in fluid communication with the inlet orifice 336, and the second intermediate wall 484 being positioned radially inward adjacent to the outer wall 324 and in fluid communication with the outlet orifice 340. Therefore, when fluid flows into the fluid pressure reducing device 400, the fluid will flow into and pass through a single common intermediate section 444, regardless of where the fluid enters the fluid pressure reducing device 400.

[0060] The single common intermediate portion 444 (which may also be referred to as the pressure recovery space) is advantageous in several ways. First, the single common intermediate portion 444 allows the device 400 to utilize the entire annular region of the portion 444 even when the valve plug is initially opened. In other words, even when the valve plug first begins to move (or to a partially or fully open position), thereby exposing one or more rows 328 of the inlet orifice 336, fluid will flow into the single common intermediate portion 444, making full use of the fully recovering (and depressurizing) region of the intermediate portion 444. Second, the single common intermediate portion 444 allows the device 400 to make full use of all outlet orifices 440, regardless of the degree to which the valve plug is open (i.e., the position of the valve plug relative to the valve seat). As an example, even when the valve plug is only at 10% stroke (i.e., has traveled 10% of the distance required to move to its fully open position), exposing both rows 328 of the inlet orifice 336, fluid will flow into and pass through the single common intermediate portion 444, which then supplies all rows 345 of the outlet orifice 340. In other words, all outlet orifices 340 can be used for pressure reduction, even if only some inlet orifices 336 are exposed. Again, and finally, a single common intermediate section 444 facilitates fluid interaction, as fluid that has passed through one inlet orifice 336 will collide with fluid that has passed through other inlet orifices 336, thereby dissipating or absorbing kinetic energy in the fluid and stabilizing the fluid before entering the outlet orifice 340.

[0061] This document describes preferred aspects of the invention, including the best modes or modes known to the inventors for carrying out the invention. While many examples are shown and described herein, it will be readily understood by those skilled in the art that the details of the various aspects are not necessarily mutually exclusive. Rather, those skilled in the art, upon reading the teachings herein, should be able to combine one or more features of one aspect with one or more features of the remaining aspects. Furthermore, it should be understood that the illustrated aspects are merely exemplary and should not be construed as limiting the scope of the invention. All methods described herein may be performed in any suitable order unless otherwise indicated herein or clearly contradicted by the context. The use of any and all examples or exemplary language (e.g., “such as”) provided herein is intended only to better illustrate one or more aspects of the invention and not to limit the scope of the invention. No language in the specification should be construed as indicating that any unclaimed element is essential for the practice of the invention.

Claims

1. A fluid pressure reducing device for use in a fluid flow control apparatus, the fluid pressure reducing device comprising: An integral body having an inner wall and an outer wall radially outwardly spaced from the inner wall, the integral body extending along a longitudinal axis and having a length defined between its top and bottom ends; and Multiple flow paths are defined between the inner wall and the outer wall of the integrated body. Each flow path includes an inlet orifice, an outlet orifice, and an intermediate portion extending between the inlet orifice and the outlet orifice, wherein at least a portion of the intermediate portion extends in a direction substantially parallel to the longitudinal axis and travels at least a majority of the length of the integrated body.

2. The fluid pressure reducing device according to claim 1, wherein, Most of the middle portion extends in that direction.

3. The fluid pressure reducing device according to claim 1, wherein, At least a portion of the middle portion extending in the vertical direction travels at least a majority of the length of the integrated body.

4. The fluid pressure reducing device according to claim 3, wherein, At least a portion of the middle portion, extending in the vertical direction, travels the substantially entire length of the integrated body.

5. The fluid pressure reducing device according to claim 1, wherein, The inlet hole of each flow path spans a first portion of the periphery of the integrated body, and the outlet hole of each flow path spans a second portion of the periphery of the integrated body, the second portion being larger than the first portion.

6. The fluid pressure reducing device according to claim 1, wherein, The inlet and outlet orifices of each flow path are oriented along an axis substantially perpendicular to the longitudinal axis.

7. The fluid pressure reducing device according to claim 1, wherein, The inlet orifice of each flow path extends along its respective first inlet axis, and the outlet orifice of each flow path extends along its respective first outlet axis, which is parallel to but spaced from its respective first inlet axis.

8. The fluid pressure reducing device according to claim 1, wherein, The intermediate portion includes a first vertical portion connected to the inlet hole and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet hole and substantially parallel to the longitudinal axis, and a plurality of intermediate holes connecting the first vertical portion and the second vertical portion and substantially perpendicular to the longitudinal axis.

9. The fluid pressure reducing device according to claim 8, wherein, The inlet and outlet holes of each flow path are positioned closer to the bottom of the integrated body than the top of the integrated body, and wherein the plurality of intermediate holes are closer to the top of the integrated body than the inlet and outlet holes of each flow path.

10. The fluid pressure reducing device according to claim 8, wherein, The first vertical portion includes a first chamber and the second vertical portion includes a second chamber that is structurally separated from the first chamber.

11. The fluid pressure reducing device according to claim 1, wherein, The first and second flow paths in the plurality of flow paths share a common intermediate section.

12. The fluid pressure reducing device according to claim 1, wherein, Each of the multiple flow paths shares a single common intermediate section.

13. The fluid pressure reducing device according to claim 1, wherein, An inlet orifice for each flow path is formed in the inner wall and oriented along an inlet axis substantially perpendicular to the longitudinal axis, and an outlet orifice for each flow path is formed in the outer wall and oriented along an outlet axis substantially perpendicular to the longitudinal axis.

14. The fluid pressure reducing device according to claim 1, wherein, The basic portion of the middle section extends in the direction described.

15. The fluid pressure reducing device according to claim 1, wherein, The middle portion of the first flow path is completely separated from the middle portion of the second flow path.

16. The fluid pressure reducing device according to claim 1, further comprising a plurality of pressure limiting portions defined in the intermediate portion.

17. The fluid pressure reducing device according to claim 1, wherein the intermediate portion comprises a first vertical portion connected to the inlet portion and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet portion and substantially parallel to the longitudinal axis, and a curved portion connecting the first vertical portion and the second vertical portion.

18. The fluid pressure reducing device according to claim 17, wherein, The inlet hole and the outlet hole are positioned near the bottom end of the integrated body, and the curved portion of the middle part is positioned near the top end of the integrated body.

19. A fluid pressure reducing device for use in a fluid flow control apparatus, the fluid pressure reducing device comprising: An integrated body, the integrated body extending along a longitudinal axis and including a central opening and a peripheral portion surrounding the central opening, the peripheral portion having a top end and a bottom end opposite to the top end; Multiple flow paths are defined in the periphery of the integrated body. Each flow path includes an inlet hole, an outlet hole, and an intermediate portion connecting the inlet hole and the outlet hole. The intermediate portion extends between a bottom end and a top end, and extends in a direction substantially parallel to the longitudinal axis of the integrated body between a position near the bottom end and a position near the top end of the body. The periphery is defined by an inner wall and an outer wall radially outwardly spaced from the inner wall. The flow paths are defined between the inner wall and the outer wall. Each inlet hole is formed in the inner wall and the outlet hole is formed in the outer wall. Each inlet hole is oriented along an inlet axis substantially perpendicular to the longitudinal axis, and each outlet hole is oriented along an outlet axis substantially perpendicular to the longitudinal axis.

20. The fluid pressure reducing device according to claim 19, wherein, The first and second flow paths in multiple flow paths share a common intermediate section.

21. The fluid pressure reducing device according to claim 19, wherein, The inlet hole of each flow path spans a first portion of the periphery of the integrated body, and the outlet hole of each flow path spans a second portion of the periphery of the integrated body, the second portion being larger than the first portion.

22. The fluid pressure reducing device according to claim 19, wherein, The integrated body has a length defined from the top end to the bottom end, and wherein the middle portion spans at least a majority of the length of the integrated body.

23. The fluid pressure reducing device according to claim 22, wherein, The middle portion spans the entire length of the integrated body.

24. The fluid pressure reducing device according to claim 19, wherein, The inlet orifice of each flow path extends along its respective first inlet axis, and the outlet orifice of each flow path extends along its respective first outlet axis, which is parallel to but spaced from its respective first inlet axis.

25. The fluid pressure reducing device according to claim 19, wherein, The intermediate portion includes a first vertical portion connected to the inlet hole and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet hole and substantially parallel to the longitudinal axis, and a plurality of intermediate holes connecting the first vertical portion and the second vertical portion and substantially perpendicular to the longitudinal axis.

26. The fluid pressure reducing device according to claim 25, wherein, The inlet and outlet holes of each flow path are positioned closer to the bottom than the top, and the plurality of intermediate holes are closer to the top than the inlet and outlet holes of each flow path.

27. The fluid pressure reducing device according to claim 25, wherein, The first vertical portion includes a first chamber and the second vertical portion includes a second chamber that is structurally separated from the first chamber.

28. The fluid pressure reducing device according to claim 19, wherein, The plurality of flow paths include at least a first flow path having a first length and a second flow path having a second length different from the first length.

29. The fluid pressure reducing device according to claim 19, wherein, The intermediate portion includes a first vertical portion connected to the inlet hole and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet portion and substantially parallel to the longitudinal axis, and a curved portion connecting the first vertical portion and the second vertical portion.

30. The fluid pressure reducing device according to claim 29, wherein, The inlet hole and the outlet hole are positioned near the bottom end of the integrated body, and the curved portion of the middle part is positioned near the top end of the integrated body.

31. The fluid pressure reducing device according to claim 19, wherein, The intermediate portion includes a first vertical portion connected to the inlet hole and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet hole and substantially parallel to the longitudinal axis, and a plurality of intermediate holes connecting the first vertical portion and the second vertical portion and substantially perpendicular to the longitudinal axis.

32. The fluid pressure reducing device according to claim 19, wherein, The inlet orifice has a first diameter, each of the intermediate orifices has a second diameter larger than the first diameter, and the outlet orifice has a third diameter larger than the second diameter.

33. The fluid pressure reducing device according to claim 19, wherein, The middle portion of the first flow path is completely separated from the middle portion of the second flow path.

34. A manufacturing method, comprising: Using additive manufacturing techniques to create fluid pressure reducing devices, the creation includes: An integral body is formed having an inner wall and an outer wall radially outwardly spaced from the inner wall, the integral body extending along a longitudinal axis and having a length defined between the top and bottom ends of the integral body; and A plurality of flow paths are formed in the integrated body between the inner wall and the outer wall of the integrated body. Each flow path includes an inlet orifice, an outlet orifice, and an intermediate portion extending between the inlet orifice and the outlet orifice, wherein at least a portion of the intermediate portion extends in a direction substantially parallel to the longitudinal axis and travels at least a majority of the length of the integrated body.

35. The method according to claim 34, wherein, The first and second flow paths in the plurality of flow paths share a common intermediate section.

36. The method according to claim 34, wherein, The middle portion of the first flow path is completely separated from the middle portion of the second flow path.

37. The method of claim 34, wherein, An inlet hole for each flow path is formed in the inner wall and the inlet hole is oriented along an inlet axis substantially perpendicular to the longitudinal axis, and wherein an outlet hole for each flow path is formed in the outer wall and the outlet hole is oriented along an outlet axis substantially perpendicular to the longitudinal axis.

38. The method according to claim 34, wherein, The intermediate portion includes a first vertical portion connected to the inlet portion and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet portion and substantially parallel to the longitudinal axis, and a curved portion connecting the first vertical portion and the second vertical portion.

39. The method according to claim 34, wherein, The intermediate portion includes a first vertical portion connected to the inlet hole and substantially parallel to the longitudinal axis, a second vertical portion connected to the outlet hole and substantially parallel to the longitudinal axis, and a plurality of intermediate holes connecting the first vertical portion and the second vertical portion and substantially perpendicular to the longitudinal axis.

Images