Lattice structure valve/regulator body

• US 10,281,053 B2
• Filed: 10/07/2016
• Issued: 05/07/2019
• Est. Priority Date: 10/12/2015
• Status: Active Grant

• Current Assignee: Emerson Process Managment Regulator Technologies Incorporated (Emerson Electric Company)
• Original Assignee: Emerson Process Managment Regulator Technologies Incorporated (Emerson Electric Company)
• Inventors: Griffin, Jr., James L., Wears, William E., Penkal, Bryan J.
• Primary Examiner(s): Paquette, Ian G
• Application Number:
  US15/288,855
• Publication Number:
  US 20170102089A1
• Time in Patent Office: 942 Days
• Field of Search: 2989012, 29890124, 29890131, 29890132
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/38 to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 3/1115 comprising complex forms, e.g. honeycombs
• CPC Class Codes: B22F 3/1118 comprising internal reinforcements
• CPC Class Codes: B22F 7/062 involving the connection or repairing of preformed parts
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: B23P 15/001 valves or valve housings welding B23K; valve housings per se F16K
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F16K 27/02 of lift valves for reducing the flow resistance of screw-spindle lift-valves F16K1/06
• CPC Class Codes: F16K 27/0272 valves provided with a lining
• CPC Class Codes: F16K 27/102 for lift-valves
• CPC Class Codes: F16K 27/12 Covers for housings
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method of manufacturing a body of a fluid control apparatus using additive manufacturing, the method including forming an inner wall having an outside surface and an inside surface, an area surrounding an inlet, an area surrounding an outlet, and an area surrounding a fluid flow path, wherein the inner wall provides a fluid boundary and connects the inlet and the outlet. The method further including forming a portion of the inner wall that receives a valve seat, forming a portion of the inner wall that receives a control stem and a control element, and forming a lattice structure by depositing a solidifiable material onto the inner wall in a predetermined pattern, wherein the lattice structure is three-dimensional and includes a plurality of connected lattice members.

Claims

1. A method of manufacturing a body of a fluid control apparatus using additive manufacturing, the method including:

forming an inner wall having an outside surface and an inside surface, an area surrounding an inlet, an area surrounding an outlet, and an area surrounding a fluid flow path, wherein the inner wall provides a fluid boundary and connects the inlet and the outlet;

forming a portion of the inner wall that receives a valve seat;

forming a portion of the inner wall that surrounds a bore and receives a control stem and a control element;

forming a three-dimensional lattice structure by depositing a solidifiable material onto the inner wall in a predetermined pattern, wherein the lattice structure includes a plurality of connected lattice members.

2. The method of claim 1, wherein depositing the solidifable material includes depositing the solidifiable material directly onto the inside surface of the inner wall.

3. The method of claim 1, wherein depositing the solidifable material includes depositing the solidifable material directly onto the outside surface of the inner wall.

4. The method of claim 1, wherein forming the inner wall includes the of step forming a hollow space between the outside surface and the inside surface of the inner wall.

5. The method of claim 4, wherein forming the lattice structure includes depositing a solidifiable material onto the inner wall within the hollow space.

6. The method of claim 1, further including the step of identifying a material property of a localized area of the inner wall, and providing the lattice structure to the localized area, wherein the lattice structure includes the material property of the localized area.

7. The method of claim 6, wherein the material property is a material strength requirement.

8. The method of claim 1, further including the step of reinforcing the lattice structure by providing at least one link between at least two of the plurality of lattice members.

9. The method of claim 1, wherein the step of forming the lattice structure includes connecting the plurality of connected lattice members a predetermined distance apart to achieve a predetermined density of the lattice structure.

10. A method of manufacturing a body of a fluid control apparatus, the method including:

forming an inner wall having an inside surface and an outside surface;

forming a portion of the inner wall arranged to receive a valve seat;

forming a first flange surrounding an inlet, a second flange surrounding an outlet, and a portion surrounding a fluid flow path connecting the inlet and the outlet;

forming a portion of the inner wall surrounding a bore that receives a control element and a valve stem; and

forming a lattice structure having a plurality of connected lattice members, wherein the lattice structure is attached to the inner wall.

11. The method of claim 10, including forming the lattice structure on a receiving surface, removing the lattice structure from the receiving surface, and attaching the lattice structure to the inner wall.

12. The method of claim 10, wherein forming the inner wall includes forming the inner wall and the lattice structure together by depositing a solidifiable material in multiple layers according to a predetermined design to create a three-dimensional integrated body.

13. The method of claim 10, wherein forming the lattice structure includes manufacturing the lattice structure and attaching the lattice structure to the inside surface of the inner wall to modify the fluid flow path.

14. The method of claim 10, wherein forming the lattice structure includes manufacturing the lattice structure and attaching the lattice structure to the outside surface of the inner wall.

15. The method of claim 10, further including the step of providing a nonporous material for the inner wall and a porous material for the lattice structure.

16. The method of claim 10, further including the step of providing a gel, gas, or fluid disposed within the lattice structure for insulation.

17. The method of claim 10, further including the step of providing a sensor disposed within the lattice structure for sensing a leak in the inner wall.

18. The method of claim 10, further including the step of providing a housing arranged to receive an actuator assembly and a diaphragm assembly, wherein the housing is configured to attach to the inner wall.