Trim and associated valve and method for creating a pressure drop in a target fluid - Patents.com

Abstract

A valve configured to induce a pressure drop in a subject fluid may include an inlet, a valve seat, an outlet, and a valve trim located about the valve seat and sandwiched between the inlet and the outlet. The valve trim may include an annulus including a monolithic, monolithic porous material defining a serpentine interconnected space extending radially through the annulus. The pores in the exterior of the monolithic, monolithic porous material are arranged in a close-packed hexagonal spatial lattice.

Description

[Technical field]

[0001] (Priority Claim) This application claims the benefit of the filing date of U.S. patent application Ser. No. 17 / 217,494, filed March 30, 2021, for “TRIMS FOR PRODUCING PRESSURE DROPS IN SUBJECT FLUIDS AND RELATED VALVES AND METHODS.”

[0002] FIELD OF THEINVENTION The present disclosure relates generally to trim for a valve that may be configured to create a pressure drop and regulate the flow of fluid through the valve. More specifically, the disclosed embodiments relate to trim for a valve that may reduce turbulence in the fluid downstream of the trim, induce a more laminar flow in the fluid downstream of the trim, and reduce large, potentially damaging vibrations. Summary of the Invention [Problem to be solved by the invention]

[0003] A valve for regulating the flow of fluid in a system may be configured to induce a predetermined pressure drop across the valve. One technique for inducing such a pressure drop is to include a so-called "trim" in the valve. The trim may be positioned between the inlet and outlet of the valve design and may conventionally define a tortuous flow path for fluid to flow through to create the pressure drop. For example, conventional trims known to the inventors may be generally configured as a hollow right cylinder that surrounds a valve seat proximate the inlet of the valve and may be surrounded by a volume that leads to the outlet of the valve. Such conventional trims may be formed by stacking annular discs having a pattern of holes machined or otherwise formed in the discs. The manner in which the holes may overlap may define a tortuous path through which fluid may flow, allowing fluid to flow from the interior of the trim through the trim to the exterior of the trim, or vice versa. The discs may be stacked and secured together with end plates surrounding the axial ends of the trim.

[0004] Disclosure The valve trim may include an annulus having a monolithic, integral porous material defining a serpentine interconnected space extending radially therethrough, the pores in the exterior of the monolithic, integral porous material being arranged in a close-packed hexagonal spatial lattice.

[0005] A valve configured to induce a pressure drop in a subject fluid may include an inlet, a valve seat, an outlet, and a valve trim located about the valve seat and sandwiched between the inlet and the outlet. The valve trim may include an annulus having a monolithic, integral porous material defining a serpentine interconnected space extending radially through the annulus. The pores in the exterior of the monolithic, integral porous material may be arranged in a close-packed hexagonal spatial lattice.

[0006] A method of making a valve trim may involve sequentially depositing discrete amounts of material in the shape of an annulus. The discrete amounts of material may be exposed to heat to fuse the discrete amounts of material together and form a monolithic, integral porous material that defines a serpentine interconnected space extending radially through the annulus. Pores in the exterior of the monolithic, integral porous material may be defined in a close-packed hexagonal spatial lattice. [Brief description of the drawings]

[0007] While the disclosure concludes with claims that particularly point out and distinctly claim certain embodiments, the various features and advantages of embodiments within the scope of the present disclosure may be more readily ascertained from the following description when read in conjunction with the accompanying drawings, in which: [Figure 1] FIG. 1 is a cross-sectional side view of a valve including a trim in accordance with the present disclosure. [Diagram 2] FIG. 2 is a cross-sectional side view of a valve including another embodiment of a trim in accordance with the present disclosure. [Diagram 3] FIG. 3 is a schematic diagram showing the layout of a portion of a monolithic, one-piece porous material that may be used for trim. [Figure 4] FIG. 4 is a schematic side view showing the shape of another piece of monolithic, one-piece porous material that can be used for trim. [Diagram 5] FIG. 5 is a flow chart illustrating an exemplary method of making trim for a valve according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] The figures presented in this disclosure are not meant to be actual views of any particular valves, trims, or components thereof, but merely idealized representations employed to explain example embodiments. As such, the drawings are not necessarily drawn to scale.

[0009] The disclosed embodiments generally relate to trims for valves that can reduce turbulence of fluid downstream of the trim, induce more laminar flow in the fluid downstream of the trim, and reduce large, potentially damaging vibrations. More specifically, disclosed are embodiments of trims for valves that can form a tortuous flow path for a subject fluid by exhibiting a porous material through which the subject material can flow. For example, such trims may include a monolithic, one-piece porous material that defines a tortuous interconnected space through which the subject fluid can flow to create a desired pressure drop for the subject fluid. In some embodiments, such trims may include a lumped mass of material arranged in a packing pattern, such as, for example, a close-packed hexagonal packing pattern. More specifically, such trims may include a generally spherical lumped mass of material stacked in a close-packed hexagonal pattern.

[0010] In some embodiments, subsequent portions of the monolithic, integral porous material may be shaped to actively induce laminar flow in the subject fluid exiting the trim. For example, the portions of the monolithic, integral porous material adjacent the pores in the exterior of the trim may have at least a substantially pyramidal shape with the peak of the shape pointing away from the central geometric axis of the trim. Such a shape may provide a gradual transition from a tortuous path within the monolithic, integral porous material to the exterior of the trim, which may induce laminar flow in the subject fluid, or at least reduce the incidence and / or severity of turbulence.

[0011] To enable the formation of such complex geometric shaped materials with associated intricate networks of interconnected spaces through which material can flow, additive manufacturing techniques may be utilized to form the monolithic integral porous material of the trim. For example, direct metal laser sintering, electron beam melting, selective laser sintering, selective laser melting, binder jetting, powder bed fusion, or other 3D printing techniques may be utilized to selectively fix powder particles of material in place and form covalent bonds between them to form the monolithic integral porous material, and in some embodiments, fixation and bonding may occur simultaneously. As a more specific example, powders of material, optionally mixed with a binder, may be sequentially deposited in the shape of the relevant portions of the trim to form green parts, which may then be fused by exposure to heat (e.g., sintering, heat treatment) to burn off any binder material. As another more specific example, targeted portions of a powder bed of material may be exposed to heat (e.g., using a laser) or to a binder material to fix the portions in place and, optionally, fuse them together. Subsequent heat treatments and / or subtractive manufacturing techniques (eg, machining, laser cutting) may be performed on the resulting monolithic, one-piece porous material prior to deployment as trim in a valve.

[0012] The configuration of trim for a valve according to the present disclosure may reduce the likelihood that a subject fluid exiting the trim may exhibit turbulence adjacent to and within a section of pipe or tubing downstream of the valve. For example, the distribution of output pores, the shape of the tortuous path, and the shape of the outer portion of the trim of the valve according to the present disclosure may actively promote laminar flow of the fluid at least immediately adjacent to and downstream of a given trim. In some embodiments, trim according to the present disclosure may reduce the intensity or eliminate vibrations that would be generated if a stacked plate-type trim were used. Such reduction in vibrations may reduce the incidence and / or intensity of noise associated with the operation of the valve. In addition, such reduction in vibrations may reduce the risk that such vibrations would affect the movement of other components of the valve, such as the movement of the stem and the orientation and positioning of the associated plug, reducing the reliability of its control.

[0013] As used herein, the terms "substantially" and "about" with respect to a given parameter, characteristic, or condition mean and include the degree to which one of ordinary skill in the art would understand that the given parameter, characteristic, or condition will be met with some degree of variation, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially or about a particular value may be at least about 90% of the particular value, at least about 95% of the particular value, at least about 99% of the particular value, or even at least about 99.9% of the particular value.

[0014] As used herein, the term "monolithic" refers to and includes a structure formed from contiguous masses of material bonded together using chemical bonds and at least substantially devoid of contiguous surfaces of unbonded material. For example, a monolithic structure may be fabricated by sequentially positioning particles of material in predetermined locations using additive manufacturing processes (e.g., 3D printing, selective laser sintering, binder jetting) and subsequently or simultaneously fusing the particles together by chemical bonds (e.g., covalent bonds, metallic bonds) by exposure to heat, or may be cast or machined from a precursor mass of material. Subsequent processing such as heat treatment, densification (e.g., by sintering), and connection to another structure (e.g., by bonding, welding, brazing, pinning, bolting, riveting) may be performed on the monolithic structure.

[0015] The term "hexagonal close-packed" as used herein with respect to a material, structure, or other arrangement of clustered masses means and includes a shape formed by arranging a group of approximately polyhedral shapes of materials, structures, or other clustered masses in close-packed offset layers having a unit cell consisting of seven approximately polyhedral shapes (six at the vertices of a hexagon and the seventh proximate the geometric center of the hexagon). For example, a hexagonal close-packed structure may include a concentrated mass of a given material shaped at least substantially as a sphere, optionally with the spheres fused or otherwise bonded to one another to form a seven-sphere, hexagonal unit cell in a layer, with adjacent layers stacked on top of one another and offset by no more than about 1.1 times the radius of the spheres, with some intersections between adjacent spherical shapes, as alternating layers have polyhedral shapes that are approximately aligned with one another.

[0016] As used herein, the term "hexagonal close-packed" with respect to a space lattice means and includes an interconnected network of three-dimensional space, whether occupied or unoccupied by materials (e.g., voids, environmental fluids such as air, permeated solid materials) located between materials, structures, or other clustered masses in a close-packed hexagonal arrangement. For example, a close-packed hexagonal space lattice may itself form a pattern, with the openings, spaces (occupied or unoccupied), pores, or voids of the close-packed hexagonal space lattice being located at the vertices of a hexagonal shape that surrounds a given concentrated mass of the close-packed hexagonal material, structure, or other clustered mass.

[0017] FIG. 1 is a cross-sectional side view of a valve 100 including a trim 110 according to the present disclosure. In some embodiments, the valve 100 may be configured as a globe valve, generally as shown in FIG. 1. For example, the valve 100 may include a housing 104 in which and on which other components of the valve 100 may be supported and which may optionally define an internal fluid passage to form a portion of a fluid path through the valve 100. For example, the housing 104 may define an inlet 112 for receiving an incoming subject fluid into the valve 100 and an outlet 114 for allowing the subject fluid to exit the valve 100. The housing 104 may support a bonnet 116, which may support a stem 102 that is movable relative to the bonnet 116. The plug 106 may be secured to the stem 102 such that movement of the stem 102 may induce a corresponding movement of the plug 106. The plug 106 may be selectively engaged and disengaged with a valve seat 108 defined or supported by the housing 104 to seal, open, and optionally control the flow of a target fluid through the valve 100. Although the valve 100 of FIG. 1 is specifically shown as a globe valve, valves according to the present disclosure, and trims 110 usable with valves contemplated in the present disclosure, may be configured as other types of valves, such as, for example, ball valves, butterfly valves, gate valves, check valves, plug valves, pinch valves, needle valves, diaphragm valves, relief valves, solenoid valves, and the like.

[0018] The trim 110 may be sandwiched between the inlet 112 and outlet 114 of the valve 100. For example, the trim 110 may be located between a mechanism for opening and closing the valve 100 and the outlet 114 of the valve. More specifically, the trim 110 may be generally shaped as a hollow prism that is located at least partially around the valve seat 108, at least a portion of the plug 106, and a portion of the stem 102, such that any fluid of interest that passes through a space defined between the plug 106 and the valve seat 108 may flow through the trim 110 before reaching the outlet 114. As a specific, non-limiting example, the trim 110 may be generally shaped as a hollow right cylinder, the trim 110 may surround at least a portion of the valve seat 108, at least a portion of the plug 106, and a portion of the stem 102, and any target fluid flowing between the valve seat 108 and the plug 106 may encounter and be required to flow through the trim 110 as it travels from the inlet 112 toward the outlet 114.

[0019] The trim 110 may include a monolithic, integral porous material 200 that defines a serpentine interconnected space through which the subject fluid may flow to create a pressure drop for the subject fluid across the trim 110. For example, those portions of the trim 110 through which the subject fluid may be flowable may be formed from a concentrated interconnected mass of material, defining a network of pores between the concentrated interconnected mass of material, allowing the subject fluid to flow through the trim 110 while providing a selectable strength of resistance to that flow and a corresponding selectable pressure drop across the trim 110. More specifically, the trim 110 may include one or more end plates 118 located at opposing longitudinal ends of the trim 110 and blocking flow of the subject fluid in any direction other than from the inlet 112 to the outlet 114, a bore 120 through which the incoming subject fluid may be introduced into pores of a monolithic, one-piece porous material 200 exposed at a surface of the trim 110 defining the bore 120, and a monolithic, one-piece porous material 200 extending between the end plates 118 and defining the bore 120, defining an interconnected network of pores through which the subject fluid may flow from near the inlet 112 toward the outlet 114, defining a tortuous path that creates a predetermined pressure drop for the subject fluid across the trim 110. As a specific, non-limiting example, the end plates 118 may be located above and below the annulus 122 of the monolithic, integral, porous material 200 when the trim 110 is in the orientation shown in Figure 1, and the monolithic, integral, porous material 200 may be formed primarily utilizing a single additive manufacturing process with optional supplemental subtractive manufacturing, heat treating, densification, and / or other subtractive manufacturing (e.g., to fuse the end plates 118 to the annulus 122). The trim 110 may not include adjacent plates having overlapping recesses or holes formed by a subtractive manufacturing process, and the serpentine flow paths may similarly not include portions defined by surfaces formed by applying a subtractive manufacturing process to plates or disks and stacking the plates or disks on top of each other.

[0020] The monolithic, integral porous material 200 of the trim 110 may define a serpentine interconnected space that allows the subject fluid to flow from near the inlet 112 toward the outlet 114. For example, the monolithic, integral porous material 200 may define a serpentine interconnected space that extends radially through the annulus 122, with the pores of the monolithic, integral porous material 200 open for fluid communication at the radially inner surface 124 and the radially outer surface 126 of the annulus 122. As a result, an incoming subject fluid within the bore 120 of the trim 110 may enter the monolithic, integral porous material 200 through the pores exposed to the radially inner surface 124 of the annulus 122, may flow radially outward through the monolithic, integral porous material 200, and may exit the trim through the pores exposed to the radially outer surface 126 of the annulus 122 toward the outlet 114.

[0021] The pressure drop inducible by the trim 110 may be selectable, at least in part, by modifying the density of the monolithic, monolithic porous material 200. For example, the density of the monolithic, monolithic porous material 200 may be less than if the annulus 122 were non-porous and would prevent all flow of fluid therethrough, and may be greater than if the monolithic, monolithic porous material 200 offered little resistance to the flow of a fluid of interest through the trim 110. More specifically, the density of the monolithic, monolithic porous material 200 may be, for example, about 7 g / cm. 3 As a specific, non-limiting example, the density of the monolithic, integral porous material 200 may be about 2.5 g / cm 3 ~about 6g / cm 3 (For example, about 3 g / cm 3 , about 4g / cm 3 , about 5g / cm 3 ) may also be used.

[0022] The pressure drop induced by the trim 110 may be selectable from a wide range of potential pressure drops achievable utilizing the monolithic, monolithic, porous material 200. In some embodiments, utilizing the monolithic, monolithic, porous material 200 may be particularly suitable for applications in which a high pressure drop is desired. For example, the monolithic, monolithic, porous material 200 may be configured to induce a pressure drop of about 99.9% or less in the subject fluid as the subject fluid flows through the serpentine interconnected space defined by the monolithic, monolithic, porous material 200 of the trim 110. In other words, the pressure of the subject fluid on the side of the trim 110 proximate the outlet 114 may be about 0.1% or more of the pressure of the subject fluid on the side of the trim 110 proximate the inlet 112. More specifically, the monolithic, monolithic, porous material 200 may be configured to induce a pressure drop of about 90% to about 99.6% in the subject fluid as the subject fluid flows through the serpentine interconnected space. As a specific, non-limiting example, the monolithic, integral porous material 200 may be configured to induce a pressure drop of between about 92.5% and about 99.5% (e.g., about 95%, about 98%, about 99%) in the subject fluid as the subject fluid flows through the serpentine interconnected spaces.

[0023] The monolithic, monolithic, porous material 200 of the trim 110 may be configured to reduce the incidence and / or severity of turbulent flow in the subject fluid downstream of the trim 110. For example, the distribution of pores at the radially outer surface 126 of the annulus 122 may reduce the likelihood that interactions between adjacent localized flows of the subject fluid exiting adjacent pores at the radially outer surface 126 of the trim 110 will induce turbulent flow in the subject fluid proximate and downstream of the trim 110. As another example, the distribution of pores at the radially outer surface 126, and optionally the shape of those portions of the monolithic, monolithic, porous material 200 at the radially outer surface 126 that define pores therebetween, may actively induce laminar flow in the subject fluid proximate and downstream of the annulus 122.

[0024] Such reduction in turbulence, and potentially active induction of laminar flow, may reduce the likelihood that the flow of the subject fluid through the valve 100, and particularly through the trim 110, will cause vibrations in the valve 100 itself, as well as in the piping and other components upstream and downstream of the valve 100. For example, the reduction in turbulence enabled by the trim 110 in accordance with the present disclosure may reduce the likelihood that vibrations may cause unintended relative movement between components of the valve 100, such as between the stem 102 and the bonnet 116, which may increase the reliability and accuracy of operation of the valve 100, especially over long periods of time. Additionally, the reduction in turbulence enabled by the trim 110 in accordance with the present disclosure may reduce the likelihood that vibrations may create loud and disruptive audible noises in the vicinity of the valve 100.

[0025] The trim 110 material may depend, at least in part, on the application of the valve 100 and associated trim 110. For example, the trim 110 material may be chemically non-reactive with the target fluid intended to be used with the valve 100, may be a medical grade material, and / or may be configured to operate stably upon exposure to temperature, pressure, and other environmental conditions in the intended application. More specifically, the trim 110 material may be capable of being positioned into the shape of the porous annular body 122 by an additive manufacturing process and may have strength, density, and reactivity properties suitable for use in the anticipated application. As specific, non-limiting examples, the trim 110 material may include metals, metal alloys, ceramics, polymers, and / or composites or solid solutions thereof (e.g., stainless steel, tungsten carbide particles in a metal matrix material, sandstone). In some embodiments, the monolithic integral porous material 200 of the trim 110 may not be homogenous. For example, the density, material type, or relative concentration of materials in a composite or solid solution may be distributed in a gradient through the annulus 122, varying radially from the radially inner surface 124 to the radially outer surface 126, or varying longitudinally from one end plate 118 to the other end plate 118.

[0026] Figure 2 is a cross-sectional side view of a valve 200 including another embodiment of a trim 202 according to the present disclosure. The valve 200 of Figure 2 may be at least substantially similar to the valve 100 of Figure 1, or may employ any of the structural variations and configurations described in more detail in connection with Figure 1.

[0027] In some embodiments, the trim 202 sandwiched between the inlet 112 and the outlet 114 of the valve 200 may include a first region 204 including a porous material 208 and a second region 206 including a non-porous material 210. For example, each first region 204 including a porous material 208 may extend radially from the radially inner surface 124 to the radially outer surface 126 and longitudinally along a portion of the central geometric axis 128 of the trim 202 to form only a portion of the vertical height of the trim 202 when the trim 202 is in the orientation shown in FIG. 2. Similarly, each second region 206 may extend radially from the radially inner surface 124 to the radially outer surface 126 and longitudinally along a portion of the central geometric axis 128 of the trim 202 to form only a different portion of the vertical height of the trim 202 when the trim 202 is in the orientation shown in FIG. 2.

[0028] In some embodiments, the first regions 204 and second regions 206 may alternate longitudinally with one another. For example, each pair of first regions 204 may include a second region 206 sandwiched therebetween, and each pair of second regions 206 may include a first region 204 sandwiched therebetween. More specifically, each first region 204 and each second region 206 may generally have the shape of a portion of the annulus 122, each first region 204 may be located proximate to, abut, and be secured to an end plate 118, and the first regions 204 and second regions 206 may alternate with one another to occupy the remaining longitudinal space between the end plates 118.

[0029] The presence of the second region 206 including the non-porous material 210 in the trim 202 may reduce the likelihood that the subject fluid flowing through the porous material 208 of the first region 204 will flow in an unintended direction, reducing the efficiency of the valve 200. For example, the second region 206 may be positioned and configured to encourage the subject fluid to flow primarily from the radially inner surface 124 of the trim 202 toward the radially outer surface 126 of the trim 202, reducing the extent to which the subject fluid can flow in a direction parallel to the central geometric axis 128. More specifically, the presence, shape, and positioning of the second region 206 including the non-porous material 210 may increase the likelihood that the subject fluid flowing through the trim 202 will move primarily in a direction perpendicular to the central geometric axis 128, and reduce the likelihood that the subject fluid can move in a direction parallel to the central geometric axis 128. Encouraging the target fluid to take a more direct path through the trim 110 may increase the likelihood that the introduction of the trim 202 will have the expected effect on the pressure and flow rate of the target fluid through the valve 200.

[0030] In some embodiments, the non-porous material 210 of the second region 206 may be monolithic and integral with the porous material 208 of the first region 204. For example, the first region 204 and the second region 206 may be formed utilizing a single additive manufacturing process, with the material in the second region 206 having a higher density than the material in the first region 204. More specifically, a greater amount of material of the trim 202 may be deposited in the second region 206, or those amounts of precursor material in the second region 206 may be exposed to higher temperatures, melting or sintering temperatures for a longer period of time, or both, to cause the material in the second region 206 to become the non-porous material 210. A smaller amount of material of the trim 202 may be placed in the first region 204, or those amounts of precursor material in the first region 204 may be exposed to a lower temperature, to melting or sintering temperatures for a shorter period of time, or both, to ensure that the material in the first region 204 remains as porous material 208.

[0031] In other embodiments, the non-porous material 210 of the second region 206 may be separate and different from the porous material 208 of the first region 204. For example, the non-porous material 210 may be provided as a solid, full density annular plate or disk, and the porous material 208 may be provided as a separate porous annular plate or disk. The respective plates or disks may be stacked one on top of the other and secured to one another (e.g., by welding, brazing, adhesives, bolts, screws, pins, etc.) to form the first region 204 and the second region 206 of the trim 202.

[0032] 3 is a schematic diagram illustrating the arrangement of a portion of a monolithic, monolithic, one-piece porous material 300 usable for trim according to the present disclosure. Specifically, FIG. 3 illustrates an exemplary packing pattern of a single layer of lumped masses 302 of the monolithic, one-piece porous material 300, where the lumped masses 302 are generally shaped as spheres and the unit cells of the lumped masses 302 may be arranged in a hexagonal shape with one of the lumped masses 302 located at each vertex of the hexagon and another lumped mass 302 located at the geometric center of the hexagon. To form the monolithic, one-piece porous material 300, each layer of the lumped masses 302 may be placed adjacent to one another and the lumped masses 302 in adjacent layers may be offset from one another to provide close packing while maintaining an open network of interstitial spaces 304 between the interconnected lumped masses 302 of the monolithic, one-piece porous material 300.

[0033] In some embodiments, the monolithic, monolithic, porous material 300 may be formed by arranging the respective lumped masses 302 in a predetermined packing pattern, leaving an interconnected network of interstitial spaces 304 between the lumped masses 302. For example, at least those lumped masses 302 of the monolithic, monolithic, porous material 300 exposed at the radially outer surface 126 (see FIG. 1 ) may be arranged in a close-packed hexagonal pattern, causing the pores 306 exposed on the exterior of the monolithic, monolithic, porous material 300 to be arranged in a close-packed hexagonal spatial lattice. More specifically, the lumped masses 302 of the monolithic, monolithic, porous material 300 throughout the annulus 122 (see FIG. 1 ) may be arranged in a close-packed hexagonal pattern, causing the interstitial spaces 304 throughout the monolithic, monolithic, porous material 300 to be arranged in a close-packed hexagonal spatial lattice.

[0034] The individual prismatic shapes of the lumped masses 302 may be fused together with various degrees of overlap. For example, the lumped masses 302 may be interconnected only to the extent necessary to provide sufficient structural strength to resist flow of a subject fluid through the monolithic, integral, porous material 300, at least substantially approximating point-to-point surface connections between the lumped masses 302. As another example, the lumped masses 302 may be interconnected to a greater extent to further limit the size of the interconnected network of interstitial spaces 304 between the lumped masses 302, increasing the density of the monolithic, integral, porous material 300. More specifically, the apparent overlap between the prismatic shapes of adjacent lumped masses 302 may be about 25% or less of the radius of a given lumped mass 302. As a specific, non-limiting example, the apparent overlap between the prismatic shapes of adjacent lumped masses 302 may be about 1% to about 20% (e.g., about 5%, about 10%, about 15%) of the average radius of the two adjacent lumped masses 302.

[0035] 4 is a schematic side view illustrating the shape of another portion of a monolithic, one-piece, porous material 300 usable in a trim according to the present disclosure. In some embodiments, the shape of the portion 402 of the monolithic, one-piece, porous material 300 exposed at the radially outer surface 126 (see FIG. 1) of the trim 110 (see FIG. 1) may be configured to reduce the likelihood of a target fluid exiting the pores 306 outside of the trim 110 (see FIG. 1). For example, the portion 402 of the monolithic, one-piece, porous material 300 exposed at the radially outer surface 126 may exhibit a taper in which a maximum dimension of the given portion 402 is located proximate to the central geometric axis 128 (see FIG. 1) of the trim 110 (see FIG. 1) and a minimum dimension of the given portion 402 is located distal to the central geometric axis 128 (see FIG. 1) of the trim 110. More specifically, those portions 402 of the monolithic, integral porous material 300 adjacent the exterior pores 306 may have, for example, an at least substantially pyramidal shape, with the peak of the shape pointing away from the central geometric axis 128 (see FIG. 1) of the annular body 122 (see FIG. 1) of the trim 110 (see FIG. 1). As a specific, non-limiting example, the portions 402 of the monolithic, integral porous material 300 adjacent the exterior pores 306 may have an at least substantially conical shape.

[0036] 5 is a flow chart illustrating an exemplary method 500 of making a trim for a valve according to the present disclosure. Method 500 may involve, for example, sequentially depositing discrete amounts of material into the shape of an annulus, as shown in operation 502. More specifically, sequentially depositing discrete amounts of material into the shape of an annulus may involve, for example, depositing the discrete amounts in layers into the shape of an annulus, or bonding the discrete amounts to one another into the shape of an annulus from within a powder bed of material. As a specific, non-limiting example, the discrete amounts of material may be provided in the form of a powder, optionally mixed with or suspended in a binder material, and may be sequentially deposited by dispensing from a 3D printer head, or sequentially deposited by blanket deposition in a powder bed.

[0037] The discrete amounts of material may be exposed to heat to fuse the discrete amounts of material together and form a monolithic, integral, porous material that defines a serpentine interconnected space extending radially through the annulus, as shown in operation 504. For example, the discrete amounts of material may be exposed to heat during the placement stage, such as by directing radiation emitted by a laser toward the discrete amounts of material in a targeted manner. As another example, the discrete amounts of material may be exposed to heat following placement of all of the materials, such as by placing the green parts (i.e., unmelted, unsintered parts) in a furnace and optionally applying pressure to densify the green parts and fuse (i.e., sinter) the discrete amounts of material together. Such a process may also involve burning off any amount of binder material.

[0038] The pores may be defined in the exterior of the monolithic material in a close-packed hexagonal spatial lattice manner, as shown in operation 506. For example, at least those portions of the material located at the outlet of the trim may be arranged in a close-packed hexagonal pattern, causing the pores defined therebetween to be in a close-packed hexagonal spatial lattice manner. More specifically, at least substantially the entire lumped mass of the monolithic monolithic porous material may be fused together in a manner such that it is arranged in a close-packed hexagonal pattern, ensuring that the interconnected network of pores in the exterior and void spaces within the monolithic monolithic porous material may be in a close-packed hexagonal spatial lattice manner.

[0039] The configuration of trim for a valve according to the present disclosure, including the distribution of output pores, the shape of the tortuous path, and the shape of the outer portion of the trim for a valve according to the present disclosure, may reduce turbulence in the subject fluid at least immediately adjacent and downstream of a given trim. In some embodiments, trim according to the present disclosure may reduce the intensity or eliminate vibrations that would be generated if a stacked plate style trim were used.

[0040] Such reduction in turbulence, and potentially active induction of laminar flow, may reduce the likelihood that the flow of the subject fluid through the valve, and particularly through the trim, will cause vibrations in the valve itself, as well as in the piping and other components upstream and downstream of the valve. For example, the reduction in turbulence enabled by a trim in accordance with the present disclosure may reduce the likelihood that vibrations may cause unintended relative motion between components of the valve, such as between the stem and the bonnet, which may increase the reliability and accuracy of the operation of the valve, especially over long periods of time. Additionally, the reduction in turbulence enabled by a trim in accordance with the present disclosure may reduce the likelihood that vibrations may create loud and disruptive audible noises in the vicinity of the valve.

[0041] Such valve trim may be utilized in a variety of useful applications. For example, such valve trim may be advantageously deployed in chemical processing, medical fluid handling, oil and gas exploration, and other environments where pressure changes, precise operation of the valve, and low noise operation may be desirable. Such valve trim may be particularly useful when a large pressure drop of the subject fluid is desired.

[0042] Further non-limiting embodiments within the scope of the present disclosure include at least the following.

[0043] Embodiment 1: A valve trim comprising an annular body, the annular body including a monolithic, integral porous material defining a serpentine interconnected space extending radially through the annular body, the pores in an exterior of the monolithic, integral porous material being arranged in a close-packed hexagonal spatial lattice.

[0044] Embodiment 2: The valve trim of embodiment 1, wherein the lumped mass of monolithic, one-piece porous material is arranged in a close-packed hexagonal pattern.

[0045] Example 3: A monolithic, integral porous material having a density of about 7 g / cm 3 3. The valve trim of embodiment 1 or embodiment 2, wherein:

[0046] Embodiment 4: The density of the monolithic, integral porous material is about 2.5 g / cm 3 ~about 6g / cm 3 4. The valve trim of embodiment 3, wherein

[0047] Embodiment 5: A valve trim described in any one of embodiments 1 to 4, wherein the monolithic, one-piece porous material is configured to induce a pressure drop of about 99.9% or less in the target fluid as the target fluid flows through the serpentine interconnected space.

[0048] Embodiment 6: The valve trim of embodiment 5, wherein the monolithic, one-piece porous material is configured to induce a pressure drop of about 90% to about 99.6% in the target fluid as the target fluid flows through the serpentine interconnected space.

[0049] Embodiment 7: A valve trim described in any one of embodiments 1 to 6, wherein the portion of the monolithic, integral porous material adjacent the pores on the exterior has an at least substantially pyramidal shape, with the peak of the shape pointing away from the central geometric axis of the annular body.

[0050] Embodiment 8: A valve trim as described in embodiment 7, wherein the portion of the monolithic, integral porous material adjacent the pores at the exterior has an at least substantially conical shape.

[0051] Embodiment 9: A valve trim described in any one of embodiments 1 to 8, wherein the monolithic, one-piece porous material is configured to induce laminar flow in the target fluid downstream of the annulus.

[0052] Embodiment 10: A valve configured to induce a pressure drop in a target fluid, the valve comprising an inlet, a valve seat, an outlet, and a valve trim located around the valve seat and sandwiched between the inlet and the outlet, the valve trim comprising an annular body, the annular body including a monolithic, integral porous material defining a serpentine interconnected space extending radially through the annular body, the pores in the exterior of the monolithic, integral porous material being arranged in a close-packed hexagonal spatial lattice.

[0053] Embodiment 11: A valve as described in embodiment 10, wherein the lumped mass of monolithic, one-piece porous material is arranged in a close-packed hexagonal pattern.

[0054] Embodiment 12: The density of the monolithic, integral porous material is about 7 g / cm 3 12. A valve according to embodiment 10 or embodiment 11, wherein:

[0055] Embodiment 13: A valve described in any one of embodiments 10 to 12, wherein the monolithic, one-piece porous material is configured to induce a pressure drop of about 99.9% or less in the target fluid as the target fluid flows through the serpentine interconnected space.

[0056] Embodiment 14: A valve described in any one of embodiments 10 to 13, wherein the portion of the monolithic, integral porous material adjacent the pores on the exterior has at least a substantially pyramidal shape, with the peak of the shape pointing away from the central geometric axis of the annular body.

[0057] Embodiment 15: A method of making a valve trim, comprising: sequentially depositing discrete amounts of material in the shape of an annulus; exposing the discrete amounts of material to heat to fuse the discrete amounts of material to one another and form a monolithic, integral porous material defining serpentine interconnected spaces extending radially through the annulus; and defining pores in an exterior of the monolithic, integral porous material in a close-packed hexagonal spatial lattice.

[0058] Embodiment 16: The method of embodiment 15, wherein sequentially disposing the discrete amounts of material in the shape of the toroid comprises depositing the discrete amounts in layers in the shape of the toroid, or bonding the discrete amounts to one another in the shape of the toroid from within a powder bed of the material.

[0059] Embodiment 17: The method of embodiment 15 or embodiment 16, wherein exposing the discrete amounts of material to heat comprises sintering a green part including the discrete amounts of material in a furnace or directing radiation emitted by a laser toward the discrete amounts of material.

[0060] Embodiment 18: The method of any one of embodiments 15 to 17, further comprising fusing a lumped mass of monolithic, integral porous material such that the lumped mass is arranged in a close-packed hexagonal pattern.

[0061] Embodiment 19: The density of the monolithic integral porous material is about 7 g / cm 3 19. The method of any one of embodiments 15 to 18, further comprising:

[0062] Embodiment 20: The method of any one of embodiments 15 to 19, further comprising shaping the portion of the monolithic, integral porous material adjacent the pores at the exterior to have at least a substantially pyramidal shape, the peak of the shape pointing away from the central geometric axis of the toroid.

[0063] Although certain exemplary embodiments have been described in conjunction with the drawings, those skilled in the art will recognize and understand that the scope of the present disclosure is not limited to the embodiments expressly shown and described in this disclosure. Rather, many additions, deletions, and modifications to the embodiments described in this disclosure may be made to produce embodiments that are within the scope of the present disclosure, such as those specifically claimed, including legal equivalents. Additionally, features from one disclosed embodiment may be combined with features of another disclosed embodiment while still being within the scope of the present disclosure.

Claims

1. 1. A valve trim comprising: A ring-shaped body is provided. the annulus includes a monolithic, one-piece, porous material formed by a plurality of pieces of material assembled and interconnected to define a serpentine interconnected space extending radially through the annulus; the serpentine interconnected space includes an interconnected network of pores between the plurality of pieces of the assembled and interconnected material of the monolithic, integral porous material, the interconnected network of pores being configured to permit radial fluid flow through the annulus; some of said interconnected pores are disposed external to said monolithic, integral porous material and are arranged in a close-packed hexagonal spatial lattice.

2. 2. The valve trim of claim 1, wherein the plurality of masses of gathered and bonded material are arranged in a close-packed hexagonal pattern.

3. The density of the monolithic, integral porous material is 7 g / cm ３ 3. The valve trim of claim 1 or 2, wherein:

4. The density of the monolithic, integral porous material is 2.5 g / cm ３ 6g / cm or more ３ 4. The valve trim of claim 3, wherein:

5. 5. The valve trim of claim 1, wherein the monolithic, one-piece porous material is configured to induce a pressure drop of 99.9% or less in a subject fluid as the subject fluid flows through the serpentine interconnected space.

6. 6. The valve trim of claim 5, wherein the monolithic, one-piece porous material is configured to induce a pressure drop of greater than or equal to 90% and less than or equal to 99.6% in a subject fluid as the subject fluid flows through the serpentine interconnected space.

7. 7. The valve trim of claim 1, wherein the portion of the monolithic, one-piece porous material adjacent some of the pores in the exterior has at least a pyramidal shape, the peak of the pyramidal shape pointing away from a central geometric axis of the annulus.

8. 8. The valve trim of claim 7, wherein the portion of the monolithic, one-piece porous material adjacent some of the pores in the exterior has at least a conical shape.

9. The valve trim of claim 1 , wherein the monolithic, one-piece porous material is configured to induce laminar flow in a subject fluid downstream of the annulus.

10. 10. The valve trim of claim 1, further comprising at least one region of non-porous material sandwiched between two regions of said monolithic, integral porous material.

11. A valve trim as described in any one of claims 1 to 10, wherein the collected and bonded pieces of material are selected from the group consisting of metals, metal alloys, ceramics, polymers, and composites thereof.

12. A valve trim as described in any one of claims 1 to 11, wherein the density of the monolithic, one-piece porous material varies with a gradient in the radial direction of the annular body or in the axial direction of the annular body.

13. A valve trim as described in any one of claims 1 to 12, wherein the annular body has a first region formed from the monolithic, one-piece porous material and a second region of non-porous material.

14. A valve trim as described in claim 13, wherein the first and second regions each extend radially from a radially inner surface to a radially outer surface of the annulus and longitudinally along different portions of a central geometric axis of the annulus.

15. The valve trim of claim 14, wherein the first region and the second region are alternately arranged along a central geometric axis of the annular body.

16. The method of claim 1, further comprising: providing an end plate disposed at an axial end of the annular body; The valve trim of claim 15, wherein the first region abuts the end plate.

17. 1. A valve configured to induce a pressure drop in a target fluid, comprising: An inlet, a valve seat, and an outlet, A valve trim according to any one of claims 1 to 16 located about the valve seat and sandwiched between the inlet and the outlet.

18. 1. A method of making a valve trim, comprising the steps of: sequentially depositing discrete amounts of material in the shape of a toroid; exposing the discrete amounts of material to heat to fuse the discrete amounts of material together to form a monolithic, integral, porous material formed by a plurality of pieces of material that are brought together and bonded together to define a serpentine interconnected space extending radially through the annulus; the serpentine interconnected space includes an interconnected network of pores between the plurality of pieces of the assembled and interconnected material of the monolithic, integral porous material, the interconnected network of pores being configured to permit radial fluid flow through the annulus; A method according to claim 1, wherein some of the pores within the exterior of the monolithic, integral porous material are defined to be in a close-packed hexagonal spatial lattice.

19. 20. The method of claim 18, wherein sequentially depositing the discrete amounts of material onto the shape of the toroid comprises depositing the discrete amounts onto the shape of the toroid in layers or bonding the discrete amounts onto each other onto the shape of the toroid from within a powder bed of the material.

20. 20. The method of claim 18 or 19, wherein exposing the discrete amounts of material to the heat comprises sintering a green part including the discrete amounts of material in a furnace or directing radiation emitted by a laser towards the discrete amounts of material.

21. 21. The method of claim 20, further comprising fusing a plurality of chunks of the material so that they are arranged in a close-packed hexagonal pattern.

22. The density of the monolithic, integral porous material is 7 g / cm ３ 22. The method of any one of claims 18 to 21, further comprising the step of:

23. 23. The method of any one of claims 18 to 22, further comprising shaping a portion of the monolithic, integral porous material adjacent at least some of the pores in the exterior to have a pyramidal shape, the peak of the shape pointing away from a central geometric axis of the annulus.

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