Monolithic Fluid Component Body for Compact Leak-Resistant Flow Paths
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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 bent conduit end portions and internal flow path discontinuities, allowing for reduced size, weight, and material usage, while facilitating complex flow path arrangements and improved manufacturing efficiency.
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 connecting multiple separate valves through welding, thereby reducing construction time and eliminating potential leak points at connections.
Solution Approach 2:
The manifold body is designed with segmented flow paths that can be independently configured for different fluid control functions. The internal flow paths are divided into multiple legs and branches that can be independently routed, allowing complex fluid control functionality while maintaining a single integrated structure.
2Adaptability or versatility
If multiple valves are connected in complex configurations, then fluid control functionality is achieved, but the overall assembly size increases
Solution Approach 1:
The manifold body incorporates nested flow paths where multiple fluid control functions are integrated within a compact structure. The internal flow paths are arranged in a nested configuration with legs and branches that are contained within the overall manifold body volume, reducing the total assembly size compared to separate valve connections.
3Adaptability or versatility
If manifold body block is machined for desired flow path arrangements, then multiple valve assemblies can be installed, but the body block becomes expensive and difficult to machine
Solution Approach 1:
The manifold body utilizes three-dimensional internal flow paths that extend in multiple directions and orientations. The flow paths include vertical legs, horizontal branches, and angled connections that leverage volumetric space rather than relying on two-dimensional surface machining, making the design more adaptable while easier to manufacture.
4Adaptability or versatility
If flow paths are extended and complex (non-straight), then desired flow control is achieved, but polished surface finish requirements become difficult to maintain
Solution Approach 1:
The manifold body incorporates curved and rounded flow path transitions instead of sharp angles or straight sections. The internal flow paths feature smooth curved transitions between legs and branches, which maintain polished surface finish while achieving the desired complex flow control functionality.
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
The solution reduces assembly costs, minimizes component wear, enhances corrosion resistance, and accelerates manufacturing time by enabling the creation of complex fluid control systems with reduced size and weight, while maintaining effective fluid flow management.
Implementation Method 1
A monolithic fluid component body is created using additive manufacturing
Implementation Method 2
an extended fluid flow path having one or more discontinuities adapted to provide increases in one or more of flow shear, flow compression, and flow incidence when the fluid flow path is treated with an abrasive laden fluid
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.