DIRECT METAL LASER SINTERED FLOW CONTROL ELEMENT

• US 20090183790A1
• Filed: 01/22/2008
• Published: 07/23/2009
• Est. Priority Date: 01/22/2008
• Status: Active Grant

• Current Assignee: Control Components Incorporated (IMI PLC)
• Original Assignee: Control Components Incorporated (IMI PLC)
• Inventors: MOORE, JASON M.
• Granted Patent: US 8,826,938 B2
• Time in Patent Office: Days
• US Class Current: 137/597
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 10/66 by mechanical means
• CPC Class Codes: B22F 5/106 Tube or ring forms
• CPC Class Codes: F16K 47/08 for decreasing pressure or noise level and having a throttling member separate from the closure member , e.g. screens, slots, labyrinths
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y10T 137/86791 Piston
• CPC Class Codes: Y10T 137/87249 Multiple inlet with multiple outlet

Abstract

A flow control element comprises a cylindrical element body having a bore formed therethrough. The cylindrical element body may include inner and outer peripheral surfaces and define a plurality of tortuous flow passages which extend between the inner and outer peripheral surfaces. The flow control element is formed as a unitary structure wherein the flow passages are oriented along at least two axes. The flow control may be formed by direct to metal laser sintering wherein successive layers of powdered metallic material are solidified by applying laser energy to the selected portions until the flow element is formed as a unitary structure with a plurality of flow passages extending therethrough. The laser energy is selectively applied to the powdered metallic material according to a computer model of the flow control element.

Claims

1. A flow control element comprising:

an element body having a bore formed therethrough and defining inner and outer peripheral surfaces with a plurality of tortuous flow passages extending radially therebetween;

wherein;

the flow control element is configured as a unitary structure formed from sintered layers of powdered material; and

each of the flow passages extends through the flow control element along at least two axes.

2. The flow control element of claim 1 wherein each of the flow passages extends through the flow control element along at least three axes.

3. The flow control element of claim 1 wherein the axes are oriented orthogonally relative to one another.

4. The flow control element of claim 1 wherein at least one of the flow passages defines a plurality of substantially right angle turns along at least one of the axes.

5. The flow control element of claim 1 wherein at least one of the flow passages include a protuberance oriented substantially transversely relative to a direction of fluid flow through the flow passage.

6. The flow control element of claim 1 wherein the bore includes an inner peripheral surface having at least one annular labyrinth groove formed therein.

7. The flow control element of claim 1 wherein:

the flow control element includes a top portion, an intermediate portion and a bottom portion; and

the flow passages are disposed within the intermediate portion.

8. The flow control element of claim 1 wherein the flow passages are formed as at least two different passage patterns that vary along at least one of a height and a width of the element body.

9. The flow control element of claim 1 wherein each of the flow passages has a cross section formed in at least one of an orthogonal and a rounded configuration.

10. The flow control element of claim 9 wherein the flow passage cross section is generally expanding along a direction of fluid flow through the flow passage.

11. A valve assembly including the flow control element as defined in claim 1 comprising:

a valve housing having the flow control element mounted therewithin such that fluid flowing through the valve housing passes through the flow passages.

12. The valve assembly of claim 11 further comprising:

a valve plug slidably disposed within the bore of the element body, the valve plug being configured to regulate the quantity of flow passages through which fluid may pass.

13. A method of fabricating a flow control element comprising the steps of:

(a) providing a layer of powered metallic material;

(b) applying laser energy to portions of the layer of powdered metallic material until the portions solidify; and

(c) repeating steps (a) and (b) with successive layers of powered metallic material until the flow control element is formed as a unitary structure with a plurality of flow passages formed therein.

14. The method of claim 13 wherein step (b) comprises selectively applying laser energy to portions of the powdered metallic material according to a computer model of the flow control element.

15. The method of claim 13 wherein step (c) comprises forming the flow control element such that at least one of the flow passages defines a plurality of substantially right angle turns along at least one of three axes.

16. The method of claim 13 wherein step (c) comprises forming the flow control element such that at least one of the flow passages includes a protuberance oriented substantially transversely relative to a direction of fluid flow through the flow passage.

17. The method of claim 13 wherein step (c) comprises forming the flow control element to include an inner peripheral surface having at least one annular labyrinth groove formed therein.

18. The method of claim 13 wherein step (c) comprises forming the flow control element to include a top portion, an intermediate portion having the flow passages disposed therein, and a bottom portion.

19. A flow control element comprising:

an element body having at least one tortuous flow passage extending axially therethrough along at least two axes;

wherein;

the element body is formed of successively applied layers of powdered material, the layers being successively sintered to unitize the element body.

20. The valve housing of claim 19 wherein the flow passage of the flow control element extends along at least three axes oriented orthogonally relative to one another.