Patent ID: 12215802

DETAILED DESCRIPTION

The present disclosure is generally directed to a method of manufacturing a device that more efficiently and effectively reduces fluid pressure than conventional fluid pressure reduction devices (e.g., the stacked disks100described above) and, at the same time, is easier and less costly to manufacture than such conventional fluid pressure reduction devices. The method described herein utilizes cutting edge manufacturing techniques, e.g., additive manufacturing, to facilitate custom manufacturing of a fluid pressure reduction device such that any number of different, and complex, flow paths can be developed and incorporated into a unitary or single body, depending upon the given application.

FIG.1is a diagram of an example of a method or process100according to the teachings of the present invention. The method or process100schematically depicted inFIG.1is a method or process of custom manufacturing a fluid pressure reduction device such as a valve trim component. Like the conventional fluid pressure reduction devices described above (e.g., the stack of disks100), fluid pressure reduction devices manufactured according to the method or process100are configured to reduce the pressure of the fluid flowing therethrough, but, as described above, are more effective and efficient at doing so and, at the same time, easier and less costly to manufacture.

More specifically, the method100includes the act104of creating a customized fluid pressure reduction device, using an additive manufacturing technique, based on the given application. The additive manufacturing technique may be any additive manufacturing technique or process that builds three-dimensional objects by adding successive layers of material on a material. The additive manufacturing technique may be performed by any suitable machine or combination of machines. The additive manufacturing technique may typically involve or use a computer, three-dimensional modeling software (e.g., Computer Aided Design, or CAD, software), machine equipment, and layering material. Once a CAD model is produced, the machine equipment may read in data from the CAD file and layer or add successive layers of liquid, powder, sheet material (for example) in a layer-upon-layer fashion to fabricate a three-dimensional object. The additive manufacturing technique may include any of several techniques or processes, such as, for example, a stereolithography (“SLA”) process, a fused deposition modeling (“FDM”) process, multi-jet modeling (“MJM”) process, a selective laser sintering (“SLS”) process, an electronic beam additive manufacturing process, and an arc welding additive manufacturing process. In some embodiments, the additive manufacturing process may include a directed energy laser deposition process. Such a directed energy laser deposition process may be performed by a multi-axis computer-numerically-controlled (“CNC”) lathe with directed energy laser deposition capabilities.

The act104of creating the customized fluid pressure reduction device includes forming a unitary or single body (act108) and forming a plurality of flow paths in the unitary or single body (act112). The unitary body can be made of one or more suitable materials, such as, for example, stainless steel, aluminum, various alloys, and, by virtue of being customizable, can be any number of different shapes and/or sizes. As an example, the unitary body may take the form of a hollow cylinder defined by an inner wall and an outer wall spaced radially outward of the inner wall. The flow paths formed in the body are generally configured to reduce the pressure of a fluid flowing therethrough. As discussed above, the usage of additive manufacturing techniques to custom manufacture the fluid pressure reduction device allows the flow paths to be formed based upon the desired application. In other words, the flow paths are customizable based upon the desired application. By virtue of being customizable, the flow paths can be unique and complex, have any number of different lengths, have any number of different sizes and/or shapes in cross-section, and/or be arranged in any number of different patterns. As a result, one or more of the flow paths may be formed to intersect with one or more other flow paths, one or more of the flow paths may be formed to include or define multiple different pressure stages (e.g., a first pressure stage and a second pressure stage where pressure is less than the pressure in the first pressure stage), one or more of the flow paths may be non-horizontal (i.e., include vertical components, such that the flow path is not solely horizontal), one or more of the flow paths can vary in shape and/or size as the fluid passes therethrough, one or more of the flow paths can vary from one or more other flow paths, the length(s) of one or more flow paths can be maximized, the flow paths can be staggered or offset from one another (either horizontally or vertically) throughout the unitary body, or combinations thereof.

It will be appreciated that the act104(and the acts108,112) can be performed any number of different times. The act104can, for example, be performed multiple times so as to create multiple fluid pressure reduction devices for use in a single process control valve, with each fluid pressure reduction device created for a specific application. The act104can, alternatively or additionally, be performed multiple times so as to create fluid pressure reduction devices for use in multiple similar or different process control valves.

FIGS.2A-2Eillustrate a first example of a fluid pressure reduction device200custom manufactured using the method or process100. The fluid pressure reduction device200in this example takes the form of a valve cage that can be utilized in a process control valve. The fluid pressure reduction device200has a single or unitary body204and a plurality of flow paths208formed or defined in the unitary body204. The flow paths208are formed in the unitary body204in a manner that maximizes their length, thereby maximizing (or at least enhancing) the pressure reduction capabilities of the device200.

The body204has a central opening212and a substantially cylindrical perimeter216surrounding the central opening212. The central opening212extends along a central longitudinal axis218and is sized to receive a valve plug (not shown) that is movably disposed therein to control fluid flow through the process control valve. The substantially cylindrical perimeter216is defined by an inner wall220and an outer wall224that is spaced radially outward of the inner wall220.

As best illustrated inFIG.2B, the flow paths208are formed in a portion of the substantially cylindrical perimeter216. The degree to which the flow paths208span the perimeter216will generally depend on the travel extent of the valve plug disposed in the fluid pressure reduction device200. In this example, the flow paths208span only approximately 50% of the perimeter216, with the flow paths208formed only between a bottom end228of the perimeter216and a portion of the perimeter216that is approximately halfway between the bottom end228and a top end232of the perimeter216. In other examples, flow paths can be added or removed such that the flow paths208can span more or less of the perimeter216, respectively. As an example, additional rows of flow paths208can be added such that the flow paths208span the entire perimeter216(i.e., can be formed between the bottom end228and the top end232).

As best illustrated inFIGS.2A-2D, the flow paths208are circumferentially arranged around the central opening212. The flow paths208are arranged in a plurality of rows234within the body204, with alternating rows234of flow paths208staggered or offset from one another. Thus, as an example, flow paths208A in row234A are staggered or offset from flow paths208B in row234B, which is adjacent to row234A. Staggering the flow paths208in this manner helps to achieve a balanced fluid flow throughout the fluid pressure reduction device200, though it is not necessary that the flow paths208be staggered in this manner (or at all).

As illustrated, each of the flow paths208has a substantially circular shape in cross-section and includes an inlet section236, an outlet section240, and a curved intermediate section244extending between the inlet and outlet sections236,240. The inlet section236is formed in and proximate the inner wall220(and, thus, proximate the central opening212), and is oriented along a first axis (e.g., axis248) that is substantially perpendicular (e.g., perpendicular) to the longitudinal axis218. The outlet section240is formed in and proximate the outer wall224. The intermediate section244in this example takes the form of two identical spiral loops250that each connect the inlet section236to the outlet section240(and vice-versa). As best illustrated inFIGS.2B and2E, each loop250extends outward and upward from the inlet section236before extending inward and upward to the outlet section240, such that the outlet section240is radially aligned with but located upward of the inlet section236(i.e., the outlet section240is closer to the top end232than the inlet section236). Put another way, the outlet section240is oriented along a second axis (e.g., axis252) that is substantially perpendicular (e.g., perpendicular) to the longitudinal axis218and parallel to but vertically above the first axis (e.g., the axis248). In this manner, the loops250serve to increase (and maximize) the length of each of the flow paths208. As also illustrated inFIGS.2B and2E, each loop250has a cross-sectional flow area that increases (e.g., gradually increases) as the loop250travels from the inlet section236to the outlet section240. Thus, the outlet section240has a cross-sectional area that is greater than a cross-sectional area of the inlet section236. In this example, the cross-sectional area of the outlet section240is approximately 3 times the cross-sectional area of the inlet section236.

In other examples, the inlet section236can be formed in and proximate the outer wall224(instead of the inner wall220), and the outlet section240can be formed in and proximate the inner wall220(instead of the outer wall224), such that fluid flows in the opposite direction through the fluid pressure reduction device200. Moreover, in other examples, the loops250can extend differently than the loops250illustrated inFIGS.2B-2E. As an example, the loops250can extend downward to the outlet section240, such that the outlet section240is located below the inlet section236(and the second axis252is located below the first axis248). Alternatively or additionally, the cross-sectional areas of the inlet and outlet sections236,240, respectively, can vary. In some cases, the ratio of the cross-sectional area of the outlet section240to the cross-sectional area of the inlet section236can vary from the 3:1 ratio described herein. As an example, the ratio can be 4:1, 2:1, or some other value. In other cases, the cross-sectional area of the inlet section236can be equal to the cross-sectional area of the outlet section240.

In any case, when configured as described above, each of the flow paths208defines multiple stages of pressure reduction. More particularly, each of the flow paths208defines three stages of pressure reduction, with the first pressure stage defined by the inlet section236, the second pressure stage defined by the intermediate section244(i.e., the loops250), and the third pressure stage defined by the end of the intermediate section244and the outlet section240. When the device200is in operation (in a valve body of a process control valve), and the valve plug is moved to a partially open position (exposing some of the inlet sections236) or a fully open position (exposing all of the inlet sections236), fluid having a first fluid pressure flows into the exposed inlet sections236of the flow paths208via the central opening212. The fluid will then flow into the intermediate section244of each flow path208. The intermediate section244distributes the fluid into the two loops250, such that the fluid is divided or separated and travels around the loops250. As this happens, the loops250force the flow to drag across or along an outer profile thereof while the fluid travels upward to the outlet section240, such that gravity acts on the fluid, thereby reducing the velocity of the fluid, reducing the kinetic energy of the fluid, and, in turn, reducing the pressure of the fluid to a second fluid pressure that is less than the first fluid pressure. As the loops250converge toward the common outlet section240, thereby rejoining the separated fluid, fluid that has passed through one of the loops250will collide with fluid that has through the other loop250of each flow path208. The fluid collisions dissipate energy in the fluid, effecting a further reduction in the pressure of the fluid, i.e., reducing the pressure of the fluid to a third fluid pressure that is less than the second fluid pressure.

FIGS.3A-3Cillustrate a second example of a fluid pressure reduction device300custom manufactured using the method or process100. The fluid pressure reduction device300in this example also takes the form of a valve cage that can be utilized in a process control valve. Like the pressure reduction device200, the fluid pressure reduction device300has a single or unitary body304and a plurality of flow paths308formed or defined in the unitary body304in a manner that maximizes their length, thereby maximizing (or at least enhancing) the pressure capabilities of the device300.

The single or unitary body304is substantially identical to the single or unitary body204discussed above, with common reference numerals used to refer to common components. The plurality of flow paths308are, like the flow paths208, divided into rows that are staggered or offset relative to one another (e.g., row334A of flow paths308is offset from row334B of flow paths308), but the flow paths308differ from the plurality of flow paths208in the manner discussed below.

Unlike the pressure reduction device200, the fluid pressure reduction device300includes common inlet sections312and common outlet sections316for associated (e.g., adjacent) flow paths308. Each inlet section312serves as the common inlet section for two associated (e.g., adjacent) flow paths308, while each outlet section316serves as the common outlet section for the same two associated (e.g., adjacent) flow paths308. As an example, inlet section312A serves as the common inlet section for flow paths308A,308B, which are adjacent one another, while outlet section316A serves as the common outlet section for the flow paths308A,308B.

Each flow path308then includes an intermediate section320that extends between one of the common inlet sections312and one of the common outlet sections316. As illustrated, the intermediate section320of each flow path308has a gradual, semi-circular shape that does not include any abrupt directional changes (which, as is known in the art, tend to cause flow unbalance, reduce passage efficiency, and, in some cases, flashing and cavitation). As also illustrated, the intermediate section320of each flow path308has a first portion that is connected to and extends radially outwardly from the respective inlet section312and a second portion that is directly connected to the first portion and extends radially outwardly toward and is connected to the respective outlet section316. For example, the intermediate section320of flow path308A has a first portion321A that is connected to and extends radially outwardly from the inlet section312A and a second portion321B that is directly connected to the first portion and extends radially outwardly toward and is connected to the outlet section316A.

So configured, each flow path308has a gradual curved flow path that intersects with one or more adjacent flow paths308, such that fluid flowing through one flow path308collides with fluid flowing through one or more adjacent flow paths308, thereby dissipating energy in the fluid and reducing fluid pressure. In this example, each flow path308intersects with one adjacent flow path308on two occasions—once when the flow transitions from the inlet section312to the intermediate section320, and again when the flow transitions from the intermediate section320. For example, fluid flowing via flow path308B will intersect with fluid flowing via flow path308C as the fluid in each of flow paths308B,308C transitions from the respective inlet section312to the respective intermediate section320, and again as the fluid in each of flow paths308B,308C transitions from the respective intermediate section320to the respective outlet section316. In other examples, however, each flow path308can intersect with additional or different flow paths308, can intersect with one or more flow paths308only once or more than two times, and/or can intersect with one or more flow paths308at different locations in the body304.

FIG.4illustrates a third example of a fluid pressure reduction device400custom manufactured using the method or process100. The fluid pressure reduction device400in this example also takes the form of a valve cage that can be utilized in a process control valve. Like the pressure reduction device200, the fluid pressure reduction device400has a single or unitary body404and a plurality of flow paths408formed or defined in the unitary body404.

The single or unitary body404is substantially identical to the single or unitary body204discussed above, with common reference numerals used to refer to common components. The plurality of flow paths408, however, differ from the plurality of flow paths208in that (1) inlet sections412of the flow paths408decrease in length as the flow paths408move away from the bottom end228of the body404and toward the top end232of the body404, (2) outlet sections416of the flow paths408increase in length as the flow paths408move away from the bottom end228of the body404and toward the top end232of the body404, and (3) the orientation of the outlet sections416relative to the longitudinal axis218changes (in this case, the angle therebetween decreases) as the flow paths408move away from the bottom end228of the body404and toward the top end232of the body404. As a result, an inlet section412A will have a smaller travel range than an inlet section4128that is closer to the bottom end232, and an outlet section416A (e.g., associated with the inlet section412A) will have a greater travel range than an outlet section4168that is closer to the bottom end228.

It will be appreciated that when fluid flows through the flow paths408, the flow paths408reduce the pressure of the fluid in a similar manner as the flow paths208described above. However, in some cases, because the flow paths408utilize more of the profile of the device400than the flow paths208(utilize of the profile of the device200), and because the flow paths408have a greater vertical component than the flow paths208, the device400may actually be more effective in reducing the pressure of the fluid than the device200. And beneficially, despite the fact that the outlet sections416are more spread out than the outlet sections240(to help achieve the pressure reduction), the device400does not require the use of a larger actuator (i.e., an actuator with a longer travel stroke), because the positioning of the inlet sections412is consistent with the positioning of the outlet sections236.

Preferred aspects of this invention are described herein, including the best mode or modes known to the inventors for carrying out the invention. Although numerous examples are shown and described herein, those of skill in the art will readily understand that details of the various aspects need not be mutually exclusive. Instead, those of skill in the art upon reading the teachings herein should be able to combine one or more features of one aspect with one or more features of the remaining aspects. Further, it also should be understood that the illustrated aspects are exemplary only, and should not be taken as limiting the scope of the invention. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the aspect or aspects of the invention, and do not pose a limitation on the scope of the invention. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.