Monolithic Valve Attenuation Element for Cavitation Control
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Solution Overview
Problem
Conventional cavitation/aerodynamic control devices for valves are costly and difficult to produce due to their complex assembly and require thick tubes, which reduces their effectiveness in reducing cavitation and increases material costs.
Innovation Solution
An anti-cavitation element comprising integrally formed hollow tubes with optimized cross-sectional shapes and geometry, fabricated using additive manufacturing techniques, which allows for thinner, stronger structures that enhance flow capacity and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cavitation control devices use bundled tubes with metal shroud and vacuum brazing, then structural integrity is achieved, but production time and cost increase significantly
Solution Approach 1:
The patent merges multiple separate components (individual tubes, metal shroud, brazing material) into a single integrated lattice structure. The lattice structure combines the functions of tube bundling, structural support, and cavitation control into one monolithic component, eliminating assembly steps and reducing production complexity while maintaining structural integrity
Solution Approach 2:
The patent replaces traditional mechanical assembly processes (vacuum brazing, welding, mechanical fastening) with additive manufacturing technology. This substitution enables the creation of complex lattice structures that would be difficult or impossible to produce with conventional mechanical methods, significantly reducing production time and cost
2Ease of manufacture
If conventional devices use thick tubes for structural support, then manufacturing ease is improved, but cavitation reduction effectiveness decreases
Solution Approach 1:
The lattice structure implements local quality by varying tube thickness and density in different regions of the structure. Thinner tubes are used where structural support is sufficient, optimizing cavitation control effectiveness, while maintaining overall structural integrity through the distributed lattice geometry rather than requiring uniformly thick walls throughout
Solution Approach 2:
The patent employs composite material strategies by combining multiple materials with different properties within the lattice structure. Different alloy compositions or material properties can be used in different regions of the lattice to optimize both structural requirements and cavitation control performance, achieving a balance between manufacturing ease and effectiveness
3Strength
If conventional devices assemble over 300 individual tubes with shroud, then structural support is achieved, but device complexity and cost increase
Solution Approach 1:
The patent merges hundreds of individual tube components and the surrounding shroud into a single integrated lattice structure. This consolidation reduces assembly complexity from hundreds of discrete parts to one monolithic component, while the lattice geometry inherently provides structural support through its distributed framework design
Solution Approach 2:
The patent replaces complex mechanical assembly systems (tube bundling, shroud attachment, brazing operations) with additive manufacturing. This substitution eliminates the need for complex assembly equipment and processes, reducing device complexity while maintaining structural support capabilities through the digitally fabricated lattice geometry
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 anti-cavitation element effectively reduces cavitation and hydrodynamic noise while minimizing material usage and production costs, offering improved performance and efficiency compared to traditional methods.
Implementation Method 1
fluid flowing through the valve may be subject to rapid changes in pressure, and this rapid pressure change in the fluid may result in the formation of vapor cavities in low-pressure portions of the fluid, a phenomenon known as cavitation
Implementation Method 2
The cavitation/aerodynamic control device may slow and/or isolate segments of fluid flow through the valve to slow the pressure reduction and/or increase in the fluid, thereby eliminating (or reducing the likelihood) of low-pressure areas in which vapor cavities can occur in the fluid. As a consequence, hydrodynamic noise may also be attenuated by the device
Data Source
AI summary
A control valve includes a valve body, a valve seat, and a valve closure member displaceable a closed position and an open position. An attenuation element is provided and includes a plurality of hollow tubes including a first tube, a second tube and a third tube. Each tube includes a flow axis from an open first end to an open second end, and an inner surface defining a flow area and having a cross-sectional shape normal to the flow axis. A second end of the tubes is between the valve closure member and first ends of the tubes along their respective flow axes when the valve closure member is closed. The first tube, the second tube, and the third tube are integrally formed as a single, unitary structure.