DESIGN OF TORTUOUS PATH CONTROL VALVE TRIM

• US 20160102781A1
• Filed: 10/14/2014
• Published: 04/14/2016
• Est. Priority Date: 10/14/2014
• Status: Active Grant

• Current Assignee: Baker Hughes, a GE Company, LLC (Baker Hughes Company)
• Original Assignee: General Electric Company
• Inventors: Glaun, Jeremy Asher
• Granted Patent: US 9,528,632 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F16K 47/04 for decreasing pressure or noise level, the throttle being incorporated in the closure member
• 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

Abstract

A valve component for controlling fluid flow comprises a body having a first surface and a second surface. At least one tortuous flow channel extends between the first surface and the second surface. The flow channel is at least partially defined by a floor portion and a ceiling portion. The body is formed as one-piece by additive manufacturing to concurrently define the flow channel as a void space. At least one of the floor portion and ceiling portion is disposed at an acute angle relative to a plane containing a layer of material forming the body.

Claims

1. A valve component for controlling fluid flow, the valve component comprising:

a body having a first surface and a second surface;

at least one tortuous flow channel extending between the first surface and the second surface, the flow channel at least partially defined by a floor portion and a ceiling portion;

the body being formed as one-piece by additive manufacturing to concurrently define the flow channel as a void space; and

wherein at least one of the floor portion and ceiling portion being disposed at an acute angle relative to a plane containing a layer of material forming the body.

2. The valve component of claim 1, wherein the acute angle for the at least one of the floor portion and ceiling portion is at least 45°

.

3. The valve component of claim 1, wherein a cross-sectional flow area of the flow channel increases as the flow channel extends from the first surface to the second surface.

4. The valve component of claim 1, further including at least one planar surface extending between the floor portion and the ceiling portion.

5. The valve component of claim 1, further including a secondary flow channel extending from the flow channel to the second surface.

6. The valve component of claim 1, wherein a height of the flow channel is greater than a width of the flow channel.

7. The valve component of claim 1, wherein at least one of the floor portion and ceiling portion includes a planar surface.

8. The valve component of claim 1, further including a plurality of tortuous flow channels extending between the first surface and second surface of the body.

9. The valve component of claim 1, wherein at least one of the floor portion and ceiling portion of the flow channel has a pair of surfaces that intersect at an acute angle, each of the pair of surfaces also being disposed at an acute angle relative to the plane containing the layer of material forming the body.

10. The valve component of claim 1, wherein the tortuous flow channel comprises at least two sections, each section of the flow channel is offset relative to an adjacent section in a direction orthogonal to the plane containing the layer of material forming the body.

11. A trim cage for controlling fluid flow, the trim cage comprising:

a unitary body having a substantially tubular configuration with a longitudinal central axis, the body having an inner surface and an outer surface;

at least one tortuous flow channel extending through the body from the inner surface to the outer surface for fluid flow therethrough, the tortuous flow channel including at least two sections, each section of the flow channel is offset relative to an adjacent section, each section of the flow channel has an axial floor portion and axial ceiling portion; and

wherein each of the axial floor portion and axial ceiling portion are disposed at an acute angle relative to a plane extending normal to the longitudinal central axis of the body.

12. The trim cage of claim 11 wherein a cross-sectional flow area of the flow channel increases in the direction extending from the inner surface to the outer surface.

13. The trim cage of claim 11, further including at least one axially extending surface between the axial floor portion and axial ceiling portion.

14. The trim cage of claim 11, wherein the body is formed as one-piece by additive manufacturing while concurrently defining the tortuous flow channel.

15. The trim cage of claim 11, further including a plurality of tortuous flow channels extending between the inner surface and outer surface of the body.

16. The trim cage of claim 11, wherein at least one of the axial floor portion and axial ceiling portion of the flow channel has a pair of surfaces that intersect at an acute angle, each of the pair of surfaces being disposed at an angle of at least 45°

relative to the plane extending normal to the longitudinal central axis of the body.

17. A method of manufacturing a unitary trim cage, the method comprising the steps of:

providing at least one layer of material to define a body base with an inner opening surface and an outer surface;

adding successive layers of material to the body base along a lay down direction and in such a manner to maintain the inner opening surface and define at least one tortuous flow channel extending between the inner opening surface and the outer surface, the tortuous flow channel including a plurality of sections;

wherein each section of the flow channel is offset relative to an adjacent section and the surfaces defining the flow channel are accomplished without internal support, and at least a portion of each section extends at an acute angle relative to direction of additive lay down; and

adding at least one layer of material to define a body cap in such a manner to maintain the inner opening surface and the outer surface.

18. The method of claim 17, wherein the trim cage has an axis and the layers of material added being substantially in a plane extending orthogonally relative to the axis, the acute angle being at least 45°

and each section of the flow channel is offset relative to an adjacent section in the lay down direction.

19. The method of claim 17, wherein the trim cage is made by a direct metal laser melting additive layer manufacturing process.

20. The method of claim 17, wherein the material is selected from a group of metal powders comprising:

stainless steel based powders;

nickel &

cobalt based powders;

iron based powders;

titanium based powders;

aluminum based powders; and

combinations thereof.