Patent Publication Number: US-2016223117-A1

Title: Conduit having integral, monolithic flow regulation features

Description:
FIELD OF THE INVENTION 
     The present disclosure relates generally to conduits, such as pipe sections, which may be utilized for flowing fluids therethrough. In particular, the present disclosure is directed to conduits which include integral and monolithic flow regulation features therein. 
     BACKGROUND OF THE INVENTION 
     Conduits for flowing fluids therethrough, such as in appliances, plumbing applications, etc., are generally known. A plurality of conduits may be connected together by suitable connector components to form a flow path for the fluid. In appliance environments, conduits may be utilized for example as air ducts in refrigerators, or as drain lines in refrigerators, dishwashers, washing machines, etc. 
     In many cases, it is desirable for fluid flow through an appliance to be restricted in one direction, such that fluid cannot “backflow” through the conduits and flowpath defined thereby. Presently known solutions for facilitating such one-way flow are to couple one-way flow valves between adjacent conduits. These valves restrict the flow of fluid between the adjacent conduits in one direction, while allowing the flow of fluid between the adjacent conduits in an opposite direction. 
     However, this approach to facilitating one-way flow has a number of disadvantages. In particular, the number of separate components which are coupled together to provide one-way flow introduces a number of weak points in the assembly where leakage or assembly failure can occur. Additionally, because known one-way flow valves are separate components which must be coupled between adjacent conduits, the positioning of the valves relative to the conduits is limited. 
     Accordingly, improved apparatus for facilitating flow regulation through conduits is desired. In particular, flow regulation apparatus that allow for stronger resulting conduit assemblies and which allow increased positioning options would be advantageous. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
     In one embodiment, a conduit is provided. The conduit includes a body having an inner surface and an outer surface, the inner surface defining an interior. The conduit further includes a flow regulation assembly disposed within the interior. The flow regulation assembly includes an integral component that is monolithic with the body. The flow regulation assembly is configured to permit fluid flow through the interior past the flow regulation assembly in a first direction and restrict fluid flow through the interior past the flow regulation assembly in a second direction opposite to the first direction. 
     In another embodiment, an appliance is provided. The appliance includes a housing, and a duct assembly for flowing a fluid therethrough. The duct assembly includes a plurality of conduits connected together to define a flowpath for fluid therethrough. At least one of the plurality of conduits includes a body having an inner surface and an outer surface, the inner surface defining an interior. The at least one of the plurality of conduits further includes a flow regulation assembly disposed within the interior. The flow regulation assembly includes an integral component that is monolithic with the body. The flow regulation assembly is configured to permit fluid flow through the interior past the flow regulation assembly in a first direction and restrict fluid flow through the interior past the flow regulation assembly in a second direction opposite to the first direction. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
         FIG. 1  is a schematic diagram of an appliance in accordance with one embodiment of the present disclosure; 
         FIG. 2  is a side cross-sectional view of a conduit, including an integral, monolithic flow regulation assembly in an open position during flow in a first direction, in accordance with one embodiment of the present disclosure; 
         FIG. 3  is a side cross-sectional view of the conduit of  FIG. 2 , including an integral, monolithic flow regulation assembly in a closed position during flow in a second direction; 
         FIG. 4  is a perspective view of the conduit of  FIG. 2 , including an integral, monolithic flow regulation assembly in a closed position during flow in a second direction; 
         FIG. 5  is a side cross-sectional view of a conduit, including an integral, monolithic flow regulation assembly in an open position during flow in a first direction, in accordance with another embodiment of the present disclosure; 
         FIG. 6  is a side cross-sectional view of the conduit of  FIG. 5 , including an integral, monolithic flow regulation assembly in a closed position during flow in a second direction; 
         FIG. 7  is a perspective view of the conduit of  FIG. 5 , including an integral, monolithic flow regulation assembly in an open position during flow in a first direction; 
         FIG. 8  is a side cross-sectional view of a conduit, including a flow regulation assembly having integral, monolithic components in an open position during flow in a first direction, in accordance with another embodiment of the present disclosure; 
         FIG. 9  is a side cross-sectional view of the conduit of  FIG. 8 , including a flow regulation assembly having integral, monolithic components in a closed position during flow in a second direction; 
         FIG. 10  is a cross-sectional view, along the line  10 - 10  of  FIG. 8 , of a conduit, including a flow regulation assembly having integral, monolithic components; and 
         FIG. 11  is a side cross-sectional view of a conduit, including multiple integral, monolithic flow regulation assemblies in an open position during flow in a first direction, in accordance with one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
       FIG. 1  is a schematic view of an appliance  10 . Appliance  10  may be any suitable appliance which utilizes conduits for flowing fluid therefrom, including for example a refrigerator, dishwasher, washing machine, etc. Appliance  10  generally includes a housing  12 . Further, appliance  10  may include a duct assembly  14  for flowing a fluid (which may for example be liquid or gas) therethrough. The duct assembly  14  be entirely interior to the housing  12 , entirely exterior to the housing  12 , or have interior and exterior portions and thus extend through the housing  12 . For example, in some embodiments, duct assembly  14  may be an air duct or drain line. 
     Duct assembly  14  may include a plurality of conduits  16  which may be connected together to define a flowpath  18  for fluid therethrough. The conduits  16  may be directly connected, such as for example via male and female features of the neighboring ends of the conduits  16 . Conduits in accordance with the present disclosure include, for example, pipe sections (as shown) as well as connector components such as elbows (as shown), flanges, traps, couplings, etc. 
     As discussed further in detail herein, at least one of the plurality of conduits  16  may include one or more flow regulation assemblies. Each flow regulation assembly may permit flow in one direction through the conduit and past the flow regulation assembly, and restrict flow in an opposite direction through the conduit and past the flow regulation assembly. Accordingly, flow regulation within the conduits  16  and duct assemblies  14  generally may advantageously be provided. 
     Further, flow regulation assemblies in accordance with the present disclosure are wholly or partially integral and monolithic with the body of the associated conduit  16 , and disposed entirely within the interior of the associated conduit  16 . The monolithic construction of a conduit such that the body and one or more components of an associated flow regulation assembly are formed as a single component advantageously increases the strength of the resulting conduit relative to previously known conduit assemblies having separate valves for flow regulation, because weak spots at the valve-conduit joints are eliminated. Further, the positioning of the flow regulation assemblies entirely within the interiors of the conduits advantageously increases potential options for positioning of the flow regulation assemblies, in particular in complex conduit structures such as for example, the structure illustrated in  FIG. 11 . 
     The construction of conduits  16  in accordance with the present disclosure, having flow regulation assemblies with components which are integral and monolithic with the associated bodies, has previously not been possible due to manufacturing restraints. However, the present inventors have advantageously utilized current advances in additive manufacturing techniques to develop exemplary embodiments of such conduits  16  in accordance with the present disclosure. While the present disclosure is not limited to the use of additive manufacturing to form such conduits  16 , additive manufacturing does provide a variety of manufacturing advantages, including ease of manufacturing, reduced cost, greater accuracy, etc. 
     As used herein, the terms “additively manufactured” or “additive manufacturing techniques or processes” refer generally to manufacturing processes wherein successive layers of material(s) are provided on each other to “build-up”, layer-by-layer, a three-dimensional component. The successive layers generally fuse together such as that a monolithic component is formed which may have a variety of integral sub-components. Suitable additive manufacturing techniques in accordance with the present disclosure include, for example, Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), 3D printing such as by inkjets and laserjets, Sterolithography (SLA), Direct Selective Laser Sintering (DSLS), Electron Beam Sintering (EBS), Electron Beam Melting (EBM), Laser Engineered Net Shaping (LENS), Laser Net Shape Manufacturing (LNSM) and Direct Metal Deposition (DMD). 
     Referring now to  FIGS. 2 through 11 , various embodiments of a conduit  16  in accordance with the present disclosure are illustrated. A conduit  16  includes a body  30  which defines an interior  32 . Body  30  has an inner surface  34 , which defines the interior  32 , and an opposing outer surface  36 . In some embodiments, as illustrated, body  30  may have a generally cylindrical shape. In other embodiments, body  30  may have any other suitable hollow polygonal shape. Further, body  30  may extend generally linearly, as shown in  FIGS. 2 through 10 , or generally curvilinearly, or may have various linear and curvilinear portions extending in various directions. For example,  FIG. 11  illustrates a cylindrical body with a number of linear portions having a complex shape. 
     As further illustrated in  FIGS. 2 through 11 , conduit  16  further includes one or more flow regulation assemblies  40 . Each flow regulation assembly  40  is disposed within the interior  32  of the conduit  16 . A flow regulation assembly  40  in accordance with the present disclosure may be configured to permit fluid flow through the interior  32  past the flow regulation assembly  40  in a first direction, as illustrated for example, in  FIGS. 2, 5, 7, 8 and 11 . A flow regulation assembly  40  in accordance with the present disclosure may further be configured to restrict fluid flow through the interior  32  past the flow regulation assembly  40  in a second direction opposite to the first direction, as illustrated in  FIGS. 3, 4, 6 and 9 . The first and second directions of fluid flow are illustrated by arrows in the various Figures as described. 
     Further, a flow regulation assembly  40  in accordance with the present disclosure includes one or more integral components which are monolithic with the body  30 . Accordingly, these components are connected to the body  16 , and the body  30  and these components are formed as a single, unitary component such as via additive manufacturing. In some embodiments as illustrated in  FIGS. 2 through 7  and  11 , the entire flow regulation assembly  40 , and thus all components thereof, are integral and monolithic with the body  30 . In other embodiments, as illustrated in  FIGS. 8 through 10 , certain components of the flow regulation assembly  40  are integral and monolithic with the body  30 . In these embodiments, the flow regulation assembly  40  may further include one or more non-integral components which generally free from the body  30  and translatable within the interior  32 . 
     Referring now to  FIGS. 2 through 4  as well as  FIG. 11 , one embodiment of a flow regulation assembly  40  is illustrated. In these embodiments, flow regulation assembly  40  includes a tube  50  which is integral and monolithic with the body  30 . The tube  50  may extend between a first end  52  and a second end  54 , and may taper towards the second end  54  as shown. First end  52  may extend from the inner surface  34  as illustrated, and the second end  54  may be generally cantilevered within the interior  32 . As illustrated, the second end  54  may be adjustable between an open position (see  FIGS. 2 and 11 ) wherein fluid flow through the interior  32  past the flow regulation assembly  40  is permitted and a closed position (see  FIGS. 3 and 4 ) wherein fluid flow through the interior  32  past the flow regulation assembly  40  is restricted. 
     For example, as shown, a portion of the tube  50  including the second end  54  may be divided into a plurality of tube sections  56  which may be pivotable relative to each other and the remainder of the tube  50 . When fluid is flowing in the first direction, the force of the fluid on the tube sections  56  may cause them to pivot apart, such that an aperture  58  is defined in the second end  54  for fluid flow therethrough. When fluid is flowing in the second direction, the force of the fluid on the tube sections  56  may cause them to pivot together, generally eliminating the aperture  58  such that fluid flow through the second end  54  is restricted. 
     Referring now to  FIGS. 5 through 7 , another embodiment of a flow regulation assembly  40  is illustrated. In these embodiments, flow regulation assembly  40  includes a plate  60  that is integral and monolithic with the body  30 . A portion of the edge of the plate  60  may, for example, extend from the inner surface  34 . Plate  60  may, for example, have a shape that generally confirms to the cross-sectional shape of the interior  32 . 
     In some embodiments, flow regulation assembly  40  may further include a tab  62  that is integral and monolithic with the body  30 . Tab  62  may extend from the inner surface  34 . The tab  62  may in some embodiments extend perimetrically about the entire inner surface  34 , as partially illustrated in  FIG. 7 . In alternative embodiments, tab  62  may extend perimetrically about only a portion of the inner surface  34 . 
     The plate  60  may be pivotable between an open position (see  FIGS. 5 and 7 ) wherein fluid flow through the interior  32  past the flow regulation assembly  40  is permitted and a closed position (see  FIG. 6 ) wherein fluid flow through the interior  32  past the flow regulation assembly  40  is restricted. For example, when fluid is flowing in the first direction, the force of the fluid on the plate  60  may cause it to pivot to a position such that fluid can flow through the interior  32  past the plate  60 . When fluid is flowing in the second direction, the force of the fluid on the plate  60  may cause it to pivot to a position such that fluid flow through the interior  32  past the plate  60  is generally prevented. When in the closed position due to fluid flow in the second direction, the plate  60  may contact and seat against the tab  62  to restrict fluid flow therepast as shown and/or may contact and seat against the inner surface  34  to restrict fluid flow therepast. 
     Referring now to  FIGS. 8 through 10 , another embodiment of a flow regulation assembly  40  is illustrated. In these embodiments, flow regulation assembly  40  includes a first tab  70  and a second tab  72 , each of which are integral and monolithic with the body  30 . The tabs  70 ,  72  may be spaced apart from each other within the interior  32 , such as along the first and second flow directions through the interior  32 . Tabs  70 ,  72  may each extend from the inner surface  34 . Further, each tab  70 ,  72  may extend perimetrically about the entire inner surface  34 . Accordingly, tab  70  may define a first bore  74  therethrough, and tab  72  may define a second bore  72  therethrough. As illustrated, first bore  74  may have a maximum width  75  (which may for example be a diameter) that is less than a maximum width  77  (which may for example be a diameter) of the second bore  72 . 
     In these embodiments, flow regulation assembly  40  may further include a disk  80 , which may be disposed between the first tab  70  and second tab  72 . While disk  80  may be formed with conduit  16  such as through additive manufacturing, disk  80  is not integral and monolithic with body  30 . Rather, disk  80  may be translatable within interior  32 , such as between the first tab  70  and second tab  72 . Disk  80  may be configured to permit fluid flow therepast when in contact with and seated against the second tab  72 , such that the fluid flows through the larger second bore  76 , and further configured to restrict fluid flow therepast when in contact with and seated against the first tab  70 , such that fluid flow through the smaller first bore  74  is generally prevented. Accordingly, and further, disk  80  may thus be translatable between an open position (as illustrated in  FIG. 8 ) seated against the second tab  72  wherein fluid flow through the interior  32  past the flow regulation assembly  40  is permitted and a closed position (as illustrated in  FIG. 9 ) seated against the first tab  70  wherein fluid flow through the interior  32  past the flow regulation assembly  40  is restricted. 
     For example, disk  80  may include an inner plate  82 , an outer ring  84 , and a plurality of arms  86  extending between the inner plate  82  and outer ring  84 . Apertures  88  may be defined between the arms  86  through which fluid may flow. As illustrated, disk  80  may have a maximum width  81  (which may for example be a diameter) that is greater than the maximum width  75  and less than the maximum width  77 . Further, disk  80  may have a surface area that is greater than the surface area of bore  74  and less than the surface area of bore  76 , and may have a shape that corresponds to the shapes of the bores  74 ,  76 . Accordingly, when the disk  80  is in the open position, the size differential between the larger bore  76  and smaller plate  82  may allow flow past the plate  82 , through the apertures  88  and through the bore  76 . When the disk  80  is in the closed position, the size differential between the smaller bore  74  and larger plate  82  may allow the plate  82  to generally block flow through the bore  74 . 
     Additionally, in some embodiments, a maximum length  85  of the outer ring  84  may be greater than the maximum length  83  of the inner plate  82 . This excess length  85  may be positioned such that, when the disk  80  is in the open position as illustrated in  FIG. 8 , the outer ring  84  may contact the tab  72  but the inner plate  82  may be spaced from the tab  72  and bore  76 . This may further facilitate flow past the disk  80  and through the bore  76 . When the disk  80  is in the closed position as illustrated in  FIG. 9 , the inner plate  82  may contact the tab  70 , thus generally blocking flow through the bore  74 . 
     As discussed, the body  30  and integral components of the flow regulation assembly  40  may be additively manufactured or otherwise manufactured such that they are monolithic. The body  30  and flow regulation assembly  40  (including the integral components thereof) may in exemplary embodiments be formed from a single material. Alternatively, however different materials may be utilized to form the body  30  and flow regulation assembly  40  (including the integral components thereof). In exemplary embodiments, the body  30  and flow regulation assembly  40  (including the integral components thereof) may be formed from suitable polymers, which may be identical or different. For example, body  30  may be formed from a rigid polymer, such as acrylonitrile butadiene styrene, polypropylene, polycarbonate. Components of the flow regulation assembly  40 , such as the integral components thereof, may be formed from a flexible polymer, such as a thermoplastic elastomer. In other embodiment, the body  30  and flow regulation assembly  40  (including the integral components thereof) may be formed from suitable metals or any other suitable materials, which may be identical or different. 
     Still further, in some embodiments, the hardness (which may for example be measured as a durometer or using any other suitable hardness scale) of material utilized for the integral components of the flow regulation assembly  40  may be different from the hardness of the body  30 . For example, in exemplary embodiments, the hardness of the integral components may be less than the hardness of the body  30 . In alternative embodiments, the hardness of the integral components may be greater than the hardness of the body  30 . Of course, in still further alternative embodiments, the hardness of the integral components may be equal to the hardness of the body  30 . 
     In exemplary embodiments, the difference in materials and hardness may provide the required rigidity to the body  30  while allowing various integral components of the flow regulation assembly  40  to, while being monolithic with the body  30 , be flexible and thus adjustable, pivotable, etc. within the body  30 . This may advantageously facilitate the improved flow modification features as discussed herein. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.