3D-Printed Flow Path Layout for Quiet Pressure Reduction Valves

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Solution Overview

Problem

Conventional fluid pressure reduction devices in process control systems often lead to increased noise and vibration, and are inefficient in pressure reduction due to unused space and complex manufacturing processes.

Innovation Solution

A fluid pressure reduction device manufactured using additive manufacturing techniques, featuring a unitary body with customizable flow paths that maximize pressure reduction by utilizing the entire device profile, including complex and staggered paths with pressure restrictions, reducing noise and vibration while being easier and less costly to produce.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If conventional stacked disk devices are used for pressure reduction, then pressure reduction capability is achieved, but noise and vibration levels increase

Engineering Contradiction:

Improvepressure reduction capabilityVSAvoidnoise and vibration

Core Design Contradiction:

Stress or pressureVSObject-generated harmful factors

Solution Approach 1:

The flow path is divided into multiple stages with sequential pressure reductions. Each stage includes an inlet aperture, intermediate section with restrictions, and outlet aperture, creating a multi-stage pressure reduction process that minimizes noise and vibration at each step rather than one large pressure drop

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flow paths extend in the longitudinal direction of the device rather than purely radially, utilizing the full three-dimensional space of the unitary body. This allows longer flow paths and more gradual pressure reduction stages, reducing turbulence and associated noise/vibration

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If conventional manufacturing processes are used for pressure reduction devices, then device functionality is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvedevice functionalityVSAvoidmanufacturing complexity and cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Multiple flow paths and pressure reduction stages are combined into a single unitary body manufactured as one piece using additive manufacturing. This eliminates the need to assemble multiple stacked disks or components, significantly reducing manufacturing complexity while maintaining full pressure reduction functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Additive manufacturing enables complex internal flow path geometries and intermediate sections with restrictions that would be difficult or impossible to achieve with conventional manufacturing. The manufacturing process itself is changed from subtractive (machining stacked disks) to additive (printing unitary body), reducing complexity and cost

Inventive Principle:

Principle #35Parameter changes

3Stress or pressure

If stacked disk configurations are used, then pressure reduction is achieved, but device space utilization is inefficient

Engineering Contradiction:

Improvepressure reduction efficiencyVSAvoidspace utilization

Core Design Contradiction:

Stress or pressureVSVolume of moving object

Solution Approach 1:

The flow paths utilize the longitudinal dimension of the device in addition to radial space, extending through the length of the unitary body. This three-dimensional utilization of space allows more efficient packing of flow paths and intermediate sections, maximizing pressure reduction capability within the available device volume

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The device effectively reduces fluid pressure with minimal noise and vibration, maximizing pressure reduction capabilities while minimizing manufacturing costs and space usage, outperforming conventional devices in efficiency and effectiveness.

Implementation Method 1

manufactured using additive manufacturing techniques

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

Each of the flow paths includes... a single intermediate section extending between the inlet and outlet apertures. At least a portion of the intermediate section extends in a direction that is substantially parallel to the longitudinal axis

Methodology Applied

Scientific EffectPressure reduction through flow path design: Pressure Drop

Data Source

PatentEP3631264B1Method of manufacturing a fluid pressure reduction device

Publication Date: 2021.11.03 FISHER CONTROLS INT LLC

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AI summary

A method of custom manufacturing a fluid pressure reduction device for use in a process control valve. The method includes creating the fluid pressure reduction device using an additive manufacturing technique, which 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 of the inner wall. The flow paths are formed in the body between the inner wall and the outer wall of the body. Each of the flow paths includes an inlet aperture, an outlet aperture, and an intermediate section extending between the inlet and outlet apertures. At least a portion of the intermediate section extends in a substantially vertical direction that is substantially parallel to the longitudinal axis, such that the flow paths are able to utilize previously un-used space in the device.