Layered Valve Trim Cage With Non-Intersecting 3D Flow Channels
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Solution Overview
Problem
Existing 3D printing technologies face challenges in printing tortuous flow paths that intersect between layers, leading to issues with fluid communication and the inability to manufacture certain features of valve trims, such as horizontal portions, which result in inefficiencies like noise, vibration, and material waste.
Innovation Solution
The method involves additive manufacturing using direct metal laser melting to create non-intersecting flow channels with specific cross-sectional shapes, including vertical walls and angular portions, allowing for the production of layered valve trim cages that reduce noise, vibration, and material waste by printing channels that extend over multiple planes without intersecting, thus enabling the creation of complex flow paths within a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tortuous flow paths are printed in 3D across multiple layers, then complex flow control is achieved, but fluid communication between layers occurs causing intersecting paths
Solution Approach 1:
The patent transitions from 2D planar flow paths to 3D spatial flow paths by utilizing vertical layering. Flow channels are designed to navigate through multiple layers in three-dimensional space, allowing complex flow control while maintaining path separation through strategic use of the vertical dimension.
Solution Approach 2:
The flow path is segmented into discrete channels with defined boundaries across multiple layers. Each layer contains specific flow channels that are spatially separated, and the segmentation ensures that fluid communication is maintained only within intended paths while preventing unintended intersections between layers.
2Adaptability or versatility
If traditional manufacturing methods (EDM, brazing) are used to create tortuous paths, then flow control features are achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces traditional mechanical manufacturing processes (EDM, brazing, stacking) with additive manufacturing technology. This substitution enables direct fabrication of complex 3D flow paths in a single integrated process, eliminating the need for multiple discrete manufacturing steps and significantly reducing manufacturing time and complexity.
Solution Approach 2:
The patent merges multiple manufacturing operations into a single additive manufacturing process. Instead of separately creating disks, cutting paths, stacking, and brazing, the entire valve trim with complex 3D flow channels is fabricated in one integrated process, improving productivity while maintaining geometric complexity.
3Ease of manufacture
If horizontal portions are added to resolve printing issues, then printability is improved, but space requirements increase
Solution Approach 1:
Instead of adding horizontal portions that increase spatial footprint, the patent utilizes the vertical dimension to resolve printing challenges. Flow paths are designed to navigate through the vertical stacking of layers, allowing complex tortuous paths to be achieved within a compact volume by exploiting three-dimensional space rather than expanding horizontal dimensions.
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 allows for the successful 3D printing of valve trim cages with reduced noise, vibration, and material waste, while enabling the production of complex flow paths that enhance fluid control and efficiency, and eliminates the need for brazing and disk stacking, resulting in cost and time savings.
Implementation Method 1
additive manufacturing using direct metal laser melting
Data Source
AI summary
A system may be configured to manufacture a layered cage of a trim. Some embodiments may additively manufacture, in each of a plurality of layers, a plurality of channels each having a cross section such that an amount of the layers satisfies a criterion, the cross section being defined by vertical walls, angular portions that extend from the walls, and a shaped top and/or bottom intersecting with angular portions. And the channels of one of the layers may not intersect with any other channel of any other layer of the cage.