THREE-DIMENSIONAL MANUFACTURING OF QUIETING VALVE HAVING COMPLEX PASSAGES

• US 20170138507A1
• Filed: 08/04/2016
• Published: 05/18/2017
• Est. Priority Date: 08/07/2015
• Status: Active Grant

• Current Assignee: Marotta Controls, Inc.
• Original Assignee: Marotta Controls, Inc.
• Inventors: Marotta, Patrick Aristide, Kluz, Krzysztof
• Granted Patent: US 10,302,224 B2
• Time in Patent Office: Days
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F15D 1/02 in pipes or conduits
• CPC Class Codes: F16K 27/0263 multiple way valves
• 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
• CPC Class Codes: F16K 47/14 the throttling member being a perforated membrane
• CPC Class Codes: F24F 2013/088 Air-flow straightener
• CPC Class Codes: Y10T 137/86734 With metering feature
• CPC Class Codes: Y10T 137/86791 Piston
• CPC Class Codes: Y10T 137/87877 Single inlet with multiple distinctly valved outlets

Abstract

A noise-reducing valve structure includes a unitary spindle-shaped body having a central lumen for receiving a fluid flow and a poppet member, the body having an inner diameter adjacent the central lumen and an outer diameter and a circumferentially and axially distributed plurality of radial passages adapted to be opened and closed in accordance with a guided position of the poppet member, the plurality of radial passages extending through the spindle-shaped body from the inner diameter to the outer diameter and having a gradually increasing area from the inner diameter to the outer diameter.

Claims

1. A noise-reducing valve structure, comprising:

a unitary spindle-shaped body having a central lumen for receiving a fluid flow from one end and a poppet member from another end, the body having an inner diameter adjacent the central lumen and an outer diameter; and

a circumferentially and axially distributed plurality of radial passages adapted to be opened and closed in accordance with a guided position of the poppet member, the plurality of radial passages extending through the unitary body from the inner diameter to the outer diameter and having a gradually increasing area from the inner diameter to the outer diameter.

2. The noise-reducing valve structure of claim 1, wherein each of the plurality of radial passages includes a single inlet channel that splits into additional channels.

3. The noise-reducing valve structure of claim 1, wherein each of the plurality of radial passages further comprises a connector that joins a first number of channels to a second number of channels, the first number and the second number being different.

4. The noise-reducing valve structure of claim 3, wherein the connector has a substantially square cross-section.

5. The noise-reducing valve structure of claim 3, wherein the connector is substantially frusto-conical.

6. The noise-reducing valve structure of claim 2, wherein each inlet channel progressively splits into multiple channels until at least twelve outlet channels are formed.

7. The noise-reducing valve structure of claim 2, wherein each inlet channel progressively splits into multiple channels until a plurality of outlet channels are formed, the plurality of outlet channels being arranged in rows and columns.

8. The noise-reducing valve structure of claim 2, wherein each inlet channel progressively splits into multiple channels until a plurality of outlet channels are formed, the plurality of outlet channels being arranged in a circle.

9. A noise-reducing valve structure, comprising:

a unitary spindle-shaped body having a central lumen for receiving a fluid flow from one end and a poppet member from another end, the body having an inner diameter adjacent the central lumen and an outer diameter; and

a circumferentially and axially distributed plurality of radial passages adapted to be opened and closed in accordance with a guided position of the poppet member, the plurality of radial passages extending through the spindle-shaped body from the inner diameter to the outer diameter and having a gradual branching in two dimensions.

10. The noise-reducing valve structure of claim 9, wherein each of the plurality of radial passages includes a single inlet channel that splits into additional channels.

11. The noise-reducing valve structure of claim 9, wherein each of the plurality of radial passages further comprises a series of connectors that joins a first number of channels to a second number of channels, the first number and the second number being different.

12. The noise-reducing valve structure of claim 11, wherein each of the connectors has a substantially square cross-section.

13. The noise-reducing valve structure of claim 11, wherein each of the connectors is substantially frusto-conical.

14. The noise-reducing valve structure of claim 10, wherein each inlet channel progressively splits into multiple channels until a plurality of outlet channels are formed, the plurality of channels being arranged in rows and columns.

15. The noise-reducing valve structure of claim 10, wherein each inlet channel progressively splits into multiple channels until a plurality of outlet channels are formed, the plurality of channels being arranged in a circle.

16. A method of manufacturing a noise-reducing valve structure comprising:

generating a complex, three-dimensional passage structure that gradually branches out in two dimensions;

producing a three-dimensional model of a noise-reducing valve having the complex, three-dimensional passage structure;

slicing the model into a series of two-dimensional cross-sections and relaying the cross-sections to a direct metal sintering laser machine having a moving platform, a powdered metal dispenser and a laser; and

successively (i) depositing powdered metal onto the moving platform, (ii) heating the powdered metal with a laser for each cross-section, and (iii) moving the platform downward by a distance sufficient to form the next cross-section until all cross-sections are made.

17. The method of claim 16, wherein each cross-section is approximately 20 microns in thickness.

18. The method of claim 16, wherein the complex, three-dimensional passage structure includes an inlet channel that progressively splits into multiple channels until a plurality of outlet channels are formed, the plurality of channels being arranged in rows and columns.

19. The method of claim 16, wherein the complex, three-dimensional passage structure includes an inlet channel that progressively splits into multiple channels until a plurality of outlet channels are formed, the plurality of channels being arranged in a circle.

20. The method of claim 16, wherein the complex, three-dimensional passage structure includes a series of connectors that joins a first number of channels to a second number of channels, the first number and the second number being different.