3D Tortuous Valve Trim for Compact Multi-Stage Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional multi-stage trim control valves require excessive material and costly precision machining due to their stacked disk design, which results in high size and cost, as well as the need for compression maintenance within the valve.
Innovation Solution
A flow control element optimized for additive manufacturing with nested, three-dimensional tortuous passageways that reduce the outer diameter and height by approximately 30%, eliminating the need for a stack of disks and minimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional stacked plate design is used, then tortuous flow paths can be created, but material utilization is high and device size is large
Solution Approach 1:
The patent merges multiple flow paths into a single integrated body with internal passageways, eliminating the need for separate stacked plates. The flow paths are combined within one monolithic structure, reducing the number of components and material usage while maintaining the tortuous flow path configuration for pressure drop control.
Solution Approach 2:
The patent implements nested flow paths where multiple passageways are arranged concentrically or in nested configurations within the single body. Inner and outer flow paths are positioned one within another, maximizing space utilization and reducing overall device diameter while maintaining multiple flow stages.
2Shape
If conventional stacked plate design is used, then tortuous flow paths can be created, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple plates into a single integrated body, eliminating the complexity of assembling and aligning multiple stacked plates. The flow paths that previously required separate plates are now contained within one monolithic structure with internal passageways, significantly reducing device complexity.
Solution Approach 2:
The patent transitions from a two-dimensional stacked plate arrangement to a three-dimensional single body with internal passageways. The flow paths are configured in multiple dimensions within the single body, allowing tortuous flow paths to be achieved without requiring multiple stacked components.
3Ease of operation
If conventional stacked plate design is used, then flow control can be achieved, but compression maintenance is required
Solution Approach 1:
The patent merges the flow control function into a single rigid body structure that maintains its shape without requiring external compression. The integrated design eliminates the need for compression mechanisms that would be required to maintain the stacked plate configuration, simplifying the device while maintaining flow control capability.
Solution Approach 2:
Instead of using compression to maintain the stacked plate structure, the patent inverts the approach by designing a single self-supporting body that maintains its structural integrity without compression. The structure is designed to be inherently stable rather than requiring external forces to maintain its configuration.
4Quantity of substance
If additive manufacturing is used, then material utilization is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes additive manufacturing parameters to create optimized flow path geometries that are difficult or impossible to achieve with conventional machining. The manufacturing process parameters are adjusted to produce the complex internal passageways and nested configurations efficiently, reducing material waste while maintaining the required precision through process optimization.
Data Source
AI summary
A flow control element includes an element body formed as a unitary structure and disposed about a body axis. The element body includes a first surface, a second surface in spaced relation to the first surface, and an inner peripheral surface extending between the first and second surfaces and defining a central bore extending along the body axis. The element body additionally includes an outer peripheral surface extending between the first and second surfaces in spaced relation to the inner peripheral surface. A plurality of passageways extend between the inner peripheral surface and the outer peripheral surface, with each passageway having a pair of side surfaces extending in generally opposed relation to each other and a pair of beveled surfaces extending toward each other from respective ones of the pair of side surfaces.