Ball Valve Lattice Structures for Weight Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional ball valves used in mineral extraction systems are heavy and complex to manufacture, assemble, and install due to their solid structure, which complicates fluid flow control and increases the weight of components, making them challenging to handle and transport.

Innovation Solution

The use of lattice structures within the ball valve components, such as a ball and closures, reduces weight by up to 50% while maintaining strength, and the integration of flow conditioners within the ball valve's bore to stabilize and adjust fluid flow, facilitated by additive manufacturing techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If solid structure is used in ball valve components, then strength is maintained, but weight increases and manufacturing complexity increases

Engineering Contradiction:

Improveweight of ball valve componentsVSAvoidstrength of ball valve components

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies porous lattice structures within the ball and closure components, creating a cellular internal architecture that reduces material density while preserving structural integrity. The lattice geometry provides load-bearing pathways that maintain strength despite reduced material volume, directly resolving the contradiction between weight reduction and strength maintenance.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent combines solid outer shells with internal lattice structures, creating a composite construction where the dense outer layer provides surface strength and sealing interfaces, while the porous internal lattice provides weight reduction and energy absorption, simultaneously addressing both strength and weight requirements.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If solid structure is used in ball valve components, then structural integrity is maintained, but manufacturing complexity and assembly difficulty increase

Engineering Contradiction:

Improveease of manufacturing ball valve componentsVSAvoidcomplexity of ball valve components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent integrates the lattice structure directly into the ball and closure components as integral features rather than separate attachments. This merging of the structural reinforcement elements with the main components eliminates additional assembly steps and reduces the total part count, thereby improving ease of manufacture and assembly while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If flow conditioners are integrated into the ball valve bore, then fluid flow stability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefluid flow stabilityVSAvoidcomplexity of ball valve internal structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flow conditioners are integrated into the ball valve bore as integral features of the valve body rather than separate removable components. This merging approach ensures consistent fluid flow conditioning while reducing the number of parts and assembly operations, thereby improving reliability through consistent performance while managing manufacturing complexity through design integration.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10837562B2Ball valves with lattice structures and methods of manufacture

Publication Date: 2020.11.17 CAMERSON INT CORP

AI summary

A ball for use within a ball valve includes an outer wall, an inner wall that defines a central bore, and a lattice structure positioned within an interior space defined between the outer wall and the inner wall. The ball may include one or more flow conditioners positioned within the central bore. The ball may be formed via an additive manufacturing process.