Systems and Methods for Manufacturing a Stack Trim

Abstract

A system may be configured to manufacture a layered cage of a trim. Some embodiments may additively manufacture, in each of a plurality of layers, a plurality of channels each having a cross section such that an amount of the layers satisfies a criterion, the cross section being defined by vertical walls, angular portions that extend from the walls, and a shaped top and/or bottom intersecting with angular portions. And the channels of one of the layers may not intersect with any other channel of any other layer of the cage.

1 . A system, comprising:
 a plurality of layers in a first trim, each of the layers comprising a plurality of channels, each channel having a   cross section that is defined by vertical walls, angular portions that extend from the walls, and a top formed by the angular portions,   wherein the channels of a first of the layers do not intersect with any other channel of any other layer of the first trim, and   wherein the channels and layers are provided via additive manufacturing.   
     
     
         2 . The system of  claim 1 , wherein the cross section is further defined by at least one of a flat, angled, and curved bottom. 
     
     
         3 . The system of  claim 1 , wherein a first overall volume of the first trim is greater than a second overall volume of a second trim, and wherein the second trim is replaced via the additive manufacturing. 
     
     
         4 . The system of  claim 1 , wherein the first trim is fitted into a valve that reduces at least one of cavitation, erosion, noise, vibration, flow velocity, and pressure by an amount that satisfies a criterion. 
     
     
         5 . The system of  claim 1 , wherein the channels of the first layer include (i) horizontal direction changes within a same plane and (ii) no vertical direction changes outside of the plane or (i) no horizontal direction changes within a same plane and (ii) vertical direction changes outside of the plane. 
     
     
         6 . The system of  claim 1 , wherein the layers are stacked directly on top of one another. 
     
     
         7 . (canceled) 
     
     
         8 . The system of  claim 1 , further comprising a stem of a valve that passes through a bonnet, wherein an initial actuation of the stem causes only a portion of the layers to allow a fluid to pass through the cage. 
     
     
         9 . (canceled) 
     
     
         10 . (canceled) 
     
     
         11 . A system, comprising:
 a plurality of layers in a first trim, each of the layers comprising a plurality of channels, each channel having a cross section that is defined by a bottom and a domed top that intersects the bottom,   wherein the channels of a first of the layers do not intersect with any other channel of any other layer of the first trim, and   wherein the channels and layers are provided via additive manufacturing.   
     
     
         12 . The system of  claim 11 , wherein the cross section is further defined by at least one of a flat, angled, and curved bottom. 
     
     
         13 . The system of  claim 11 , wherein the bottom has domed shape such that the cross section is an oval. 
     
     
         14 . The system of  claim 11 , wherein a first overall volume of the first trim is greater than a second overall volume of a second trim, and wherein the second trim is replaced via the additive manufacturing. 
     
     
         15 . The system of  claim 11 , wherein the first trim is fitted into a valve that reduces at least one of cavitation, erosion, noise, vibration, flow velocity, and pressure by an amount that satisfies a criterion. 
     
     
         16 . The system of  claim 11 , wherein the layers are stacked directly on top of one another. 
     
     
         17 . A system, comprising:
 a plurality of layers in a first trim, each of the layers comprising a plurality of channels, each channel having a cross section that is defined by a convex polygon,   wherein the channels of a first of the layers do not intersect with any other channel of any other layer of the first trim, and   wherein the channels and layers are provided via additive manufacturing.   
     
     
         18 . The system of  claim 17 , wherein the sides of the convex polygon are all of a same length. 
     
     
         19 . The system of  claim 17 , wherein a first overall volume of the first trim is greater than a second overall volume of a second trim, and wherein the second trim is replaced via the additive manufacturing. 
     
     
         20 . The system of  claim 17 , wherein the first trim is fitted into a valve that reduces at least one of cavitation, erosion, noise, vibration, flow velocity, and pressure by an amount that satisfies a criterion. 
     
     
         21 . The system of  claim 17 , wherein the channels of the first layer include (i) horizontal direction changes within a same plane and (ii) no vertical direction changes outside of the plane or (i) no horizontal direction changes within a same plane and (ii) vertical direction changes outside of the plane. 
     
     
         22 . The system of  claim 17 , wherein the layers are stacked directly on top of one another. 
     
     
         23 . The system of  claim 17 , further comprising a stem of a valve that passes through a bonnet, wherein an initial actuation of the stem causes only a portion of the layers to allow a fluid to pass through the cage.