Integral Trim Control Valve to Reduce Assembly Leaks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional control valves with individual trim components face manufacturing and assembly challenges due to tolerance stack-ups and increased variability, leading to potential leaks and higher servicing needs as the number of components increases.
Innovation Solution
Control valves with integral trim components, such as a single-piece valve body and bonnet, are manufactured using additive manufacturing, eliminating the need for multiple individual trim components and reducing assembly complexity and leakage paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If individual trim components are used in conventional control valves, then the valve can be assembled with replaceable serviceable components, but the manufacturing and assembly complexity increases due to tolerance stack-ups and the number of components
Solution Approach 1:
The patent integrates multiple trim components (seat, plug, stem, cage, springs, seals) into a single monolithic body formed by additive manufacturing. This merging eliminates the need for separate serviceable components while maintaining the valve's functional integrity, directly resolving the contradiction between serviceability and component complexity
Solution Approach 2:
The monolithic body performs multiple functions that were previously distributed across separate components: it serves as the valve body, contains the seat, supports the plug and stem, houses the cage and springs, and provides sealing surfaces. This multi-functionality reduces component count while maintaining operational capabilities
2Ease of manufacture
If multiple individual trim components are assembled into the valve body, then the valve can be manufactured with standardized components, but the assembly time and variability increase
Solution Approach 1:
The patent combines multiple separately manufactured trim components into a single monolithic body produced by additive manufacturing. This eliminates the need for assembling multiple standardized components, directly reducing assembly time and manufacturing variability while maintaining ease of manufacture through the additive process
Solution Approach 2:
The patent replaces the mechanical assembly system (multiple components fastened together) with an additive manufacturing system that produces the monolithic body in a single process. This substitution eliminates assembly operations entirely, resolving the contradiction between standardization and productivity
3Adaptability or versatility
If individual trim components are used with multiple assembly interfaces, then the valve can be assembled with flexible component selection, but the number of potential leakage paths increases
Solution Approach 1:
The patent merges multiple trim components with separate interfaces into a single monolithic body with integrated sealing surfaces. This eliminates the interfaces between separate components that could potentially leak, directly improving reliability while maintaining adaptability through the integrated design
Solution Approach 2:
The patent converts the potential harm of multiple interfaces (leakage paths) into a benefit by integrating all interfaces into the monolithic body structure. The interfaces that would have been potential failure points are now internal to the single component, eliminating external leakage paths
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Control valves having integral trim are disclosed. In some examples, an apparatus includes a single-piece valve body having an integral seat. In some examples, the apparatus includes a plug irremovably located within the single-piece valve body.