Biomimetic Valve Block Structure for Low-Material Process Valves
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Solution Overview
Problem
Existing process valve technologies, particularly in high-purity environments, face inefficiencies in material usage and environmental impact due to the one-time use of solid valve blocks, which do not optimize material distribution based on mechanical stress and often result in unnecessary material usage.
Innovation Solution
A valve block body with a biomimetic structure that mimics natural structures, such as bone and tree branch patterns, is designed using additive manufacturing, allowing for variable density and hierarchical support, optimizing material distribution and reducing weight while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If solid valve blocks are used in traditional process valve technology, then structural stability is ensured, but material usage is excessive and environmental footprint is increased
Solution Approach 1:
The valve block employs variable density lattice structures with different material distributions in different regions. Areas experiencing higher mechanical stresses have denser lattice structures, while low-stress areas have sparser structures. This local quality variation optimizes material usage by placing material only where structurally necessary, reducing overall material consumption while maintaining required structural stability.
Solution Approach 2:
The valve block is divided into multiple base sections connected by lattice structures rather than being a solid monolithic structure. This segmentation allows independent optimization of each section's material density based on local stress requirements, enabling significant material reduction while maintaining the overall structural integrity needed for valve operation.
2Weight of moving object
If variable density biomimetic structure is implemented, then material distribution is optimized and weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention utilizes additive manufacturing technology which allows direct fabrication of complex variable density lattice structures by digitally controlling material deposition parameters. The manufacturing process can vary density parameters layer-by-layer or region-by-region based on pre-calculated stress distributions, transforming a potentially complex manufacturing challenge into a controllable digital manufacturing process with optimized material placement.
3Strength
If hierarchical support structure with biomimetic branching pattern is used, then force transmission is optimized and mechanical strength is increased, but structural complexity increases
Solution Approach 1:
The hierarchical support structure with biomimetic branching patterns is pre-designed using computational methods that analyze stress distributions and optimize force transmission paths before manufacturing. This preliminary design phase allows the complex structural geometry to be precisely defined and manufactured using additive processes, transforming what would be a complex manual fabrication task into a streamlined digital-to-physical manufacturing workflow.
Data Source
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AI summary
A valve block body (100) is disclosed.This comprises a monolithic main body (200), wherein the monolithic main body (200) comprises a plurality of base sections (202a-b) with a respective valve seat (204a-b), wherein the valve seats (204a-b) are accessible via a respective seat opening (206a-b) of the associated base section (202a-b), wherein the monolithic main body (200) comprises at least one, in particular, planar contact surface (210) for the valve block body (100) to bear against a drive carrier (4), wherein the monolithic main body (200) comprises a plurality of process fluid connections (220a-c); and wherein the monolithic main body (200) comprises a plurality of tubular walls (230a-c), each of which defines an interior space of a respective process fluid channel (240a-c) extending from the respective seat opening (206a-b) to at least one of the process fluid connections (220a-c) and/or to at least one other of the seat openings (206a-b).A biomimetic structure(400) connects the base sections (202a-b; 202a-e), the attachment sections (260a-c; 260a-f) and the tubular walls (230a-c; 230a-f).