Monolithic Fluid Component Body With 3D-Printed Bent Conduits
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fluid control systems, such as those used in semiconductor wafer manufacturing, face challenges with time-consuming and costly construction, potential leak points, and limitations in shape and orientation of internal ports due to the use of multiple valves connected in complex configurations, which are difficult to machine and maintain.
Innovation Solution
A monolithic fluid component body is created using additive manufacturing, comprising discrete valve and conduit segments with fused perimeter walls and bent conduit end portions, allowing for reduced size, weight, and material usage, while facilitating complex internal flow paths and connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple valves are connected in complex configurations using welding or connecting, then fluid control functionality is achieved, but construction time and cost increase, and potential leak points increase
Solution Approach 1:
The patent combines multiple valve bodies into a single integrated manifold body with unified flow paths. The manifold body includes multiple inlet ports and outlet ports with internal flow paths that eliminate the need for external connections between valves, thereby reducing construction time and eliminating leak points at connections.
2Reliability
If multiple valves are connected in complex configurations, then fluid control functionality is achieved, but assembly costs and component wear increase
Solution Approach 1:
The patent integrates multiple valve functions into a single manifold body constructed from corrosion-resistant material. The unified structure eliminates multiple assembly interfaces and reduces the number of components that could corrode or wear, while the corrosion-resistant material provides enhanced durability throughout the entire assembly.
3Adaptability or versatility
If manifold body block is machined for desired flow path arrangements, then multiple valve assemblies can be installed, but machining complexity and cost increase
Solution Approach 1:
The patent employs additive manufacturing to create the manifold body, fundamentally changing the manufacturing parameter from traditional machining to 3D printing. This allows complex flow path configurations to be produced directly during the additive manufacturing process without requiring extensive post-manufacturing machining operations, thereby reducing machining complexity and cost.
4Adaptability or versatility
If flow paths are extended and/or complex (non-straight), then desired flow control is achieved, but polished surface finish requirements become difficult to maintain
Solution Approach 1:
The patent utilizes additive manufacturing to produce the manifold body, which fundamentally changes the surface finish characteristics. The additive manufacturing process inherently produces a surface finish that does not require traditional polishing, yet still achieves the desired flow control capabilities through the digitally designed complex flow paths.
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
This approach reduces assembly costs, minimizes component wear, improves corrosion resistance, and accelerates manufacturing time by eliminating the need for extensive machining, while enabling more efficient fluid flow management through optimized internal path designs.
Implementation Method 1
A monolithic fluid component body is created using additive manufacturing
Implementation Method 2
The conduit end portion is bent from the first direct to a second direction
Implementation Method 3
the upper perimeter wall of the first valve segment includes a portion that is fused with an adjacent portion of the upper perimeter wall of the second valve segment
Data Source
AI summary
A method of fabricating a fluid component body includes forming a monolithic fluid component body including a valve segment having an annular upper perimeter wall portion defining a valve cavity and a lower base portion defining first and second flow ports, and a conduit segment extending from one of the first and second flow ports and including a conduit end portion defining a tubular portion extending in a first direction and spaced apart from a remainder of the fluid component body. The conduit end portion is bent from the first direct to a second direction.