Patent Grant
7404416
The present invention relates to improved apparatuses and improved methods for creating pulsating fluid flow and methods for manufacture of those apparatuses; more specifically, the present invention relates to improved apparatuses and improved methods for expelling pulses of fluid sequentially from different ports in a repeated cycle and methods for manufacture of those apparatuses.
The prior art includes a number of devices that rely on fluid oscillation effects to create pulsating fluid flow. Generally, these devices connect to a source of fluid flow, provide a mechanism for oscillating the fluid flow between two different locations within the device and emit fluid pulses downstream of the source of fluid flow. These devices require no moving parts to generate the oscillations and have been used in various applications for which pulsating fluid flow is desired, such as massaging showerheads, flowmeters, and windshield-wiper-fluid-supply units.
A typical prior art apparatus for creating pulsating fluid flow includes body 10 with a nozzle 20 that attaches to a fluid source 30, as shown in
The jet will cling to one side of chamber 40 due to a phenomenon called the Coanda effect, explained in more detail later in this disclosure. Thus, the fluid will flow through one of the two fluid pathways 60 or 60′ at a time. Flow splitter 50 also helps guide the flow into either fluid pathway 60 or fluid pathway 60′. As the fluid flows through one fluid pathway such as fluid pathway 60, feedback passage 70 will divert a portion of the fluid and return it to chamber 40. The fluid will then disturb the fluid flow along the side of chamber 40 closest to fluid pathway 60. This disturbance will cause the fluid flow to switch to the side of the chamber closest to fluid pathway 60′. Fluid will thus leave from fluid pathway 60′, rather than from fluid pathway 60. As a result, the apparatus for creating pulsating fluid flow will emit pulses of fluid in succession from the two fluid pathways 60 and 60′, with only one fluid pathway 60 or 60′ ejecting fluid at a given time.
Generally, prior art apparatuses for creating pulsating fluid flow are manufactured from two rectangular blocks of a material suitable for the particular application. For example, if the apparatus for creating pulsating fluid flow will be used in a well bore, stainless steel blocks may be appropriate. A path for fluid flow is machined into the largest flat surface of one of the rectangular blocks. The two blocks are then joined together and the entire apparatus is lathed into a generally cylindrical form. This method of manufacture is labor-intensive and time-consuming.
Some applications for apparatuses for creating pulsating fluid flow require sharper fluid pulses than others. For example, apparatuses for creating pulsating fluid flow may be used to clean fluid flowlines or well bores. The apparatus for creating pulsating fluid flow is joined to a source of cleaning fluid and then is inserted into the flowline or well bore. Pulsating fluid flow has been found to be superior to steady fluid flow for cleaning surfaces such as the interior of a fluid flowline or well bore. Moreover, sharp fluid pulses dislodge buildup and debris from these surfaces better than less-defined fluid pulses because sharply defined pressure pulses have a higher frequency content. Prior art apparatuses, however, may not provide the pulse definition cleaning applications require. In addition, because prior art apparatuses emit fluid parallel to the nozzle, they do not always effectively clean areas located alongside the apparatus. For example, a prior art apparatus used downhole will not remove matter caked on the well bore because it will eject fluid down the center of the well bore, not at the sides.
Prior art apparatuses for creating pulsating fluid flow often exhibit erratic, weak or even no oscillation when used in submerged environments such as fluid flowlines or well bores. Prior art apparatuses generally rely on atmospheric air to boost the fluid oscillations. These apparatuses accordingly allow air to enter the path of the fluid. These apparatuses fail to provide reliable, robust fluid pulses in environments where air is unavailable, such as in fluid flowlines or well bores.
The present invention relates to improved apparatuses and improved methods for creating pulsating fluid flow and methods for manufacture of those apparatuses; more specifically, the present invention relates to improved apparatuses and improved methods for expelling pulses of fluid sequentially from different ports in a repeated cycle and methods for manufacture of those apparatuses.
In one embodiment, the present invention provides an apparatus for creating pulsating fluid flow, including an inlet into which fluid flows and a chamber having an upstream end and a downstream end. The chamber is defined by a pair of outwardly-projecting sidewalls, and the inlet is disposed at the upstream end of the chamber. This particular embodiment further includes at least two feedback passages with opposed entrances at the downstream end of the chamber and opposed exits at the upstream end of the chamber, near where the chamber joins the inlet. At least one feedback outlet leaves each of the feedback passages. A feedback cavity is disposed at the downstream end of the chamber. At least one exit flowline having an exit port leaves the at least one feedback outlet.
In one embodiment, the present invention provides an apparatus for creating a pulsating fluid flow, including an inlet into which fluid flows and a chamber with an upstream end and a downstream end. The chamber is defined by a pair of outwardly-projecting sidewalls, and the inlet is disposed at the upstream end of the chamber. The apparatus includes at least two feedback passages with opposed entrances at the downstream end of the chamber and opposed exits at the upstream end of the chamber, near where the chamber joins the inlet. A feedback cavity is disposed at the downstream end of the chamber, and at least one exit flowline having an exit port leaves each of the feedback passages.
In one embodiment, the present invention provides an apparatus for creating pulsating fluid flow, including an inlet into which fluid flows disposed between opposed cusps. The apparatus further includes an oscillation cavity defined by a concave rear wall and two opposed exit flowlines leaving the oscillation cavity near the inlet and opposed cusps. Each of the two opposed exit flowlines has an exit port, and the two opposed exit flowlines curve such that a portion of each of the two opposed exit flowlines is substantially perpendicular to the inlet.
In one embodiment, the present invention provides an apparatus for creating pulsating fluid flow, including an inlet into which fluid flows and a chamber having an upstream end and a downstream end. The chamber is defined by a pair of outwardly-projecting sidewalls, and the inlet is disposed at the upstream end of the chamber. The apparatus further includes at least two feedback passages with opposed entrances at the downstream end of the chamber and opposed exits at the upstream end of the chamber near where the chamber joins the inlet. Two exit flowlines leave the downstream end of the chamber. The two exit flowlines outwardly diverge from the flow of fluid into the inlet.
In one embodiment, the present invention provides a method of creating a pulsating fluid flow, including injecting a fluid through an inlet from a fluid flowline and directing the fluid into a chamber. The method further includes directing a portion of the fluid through at least two feedback passages that leave the chamber and return the chamber, forcing the fluid to oscillate inside the chamber. The method also includes directing the remaining fluid into a feedback cavity and redirecting the remaining fluid from the feedback cavity to the chamber to strengthen the fluid's oscillation. The method includes directing the fluid through at least one feedback outlet leaving each of the feedback passages and discharging the fluid through at least one exit flowline leaving the at least one feedback outlet to form a pulsating jet.
In one embodiment, the present invention provides a method of creating a pulsating fluid flow, including injecting a fluid through an inlet from a fluid flowline and directing the fluid into a chamber having an upstream end and a downstream end. The chamber is defined by a pair of outwardly-projecting sidewalls, and the inlet is disposed at the upstream end of the chamber. The method further includes directing a portion of the fluid through at least two feedback passages. The two feedback passages have opposed entrances at the downstream end of the chamber and opposed exits at the upstream end of the chamber near where the chamber joins the inlet. The method also includes directing the remaining fluid into a feedback cavity disposed at the downstream end of the chamber and redirecting the remaining fluid from the feedback cavity disposed at the downstream end of the chamber back to the chamber to strengthen the fluid's oscillation. The method includes directing the fluid through at least one feedback outlet leaving each of the feedback passages and discharging the fluid through at least one exit flowline that has an exit port and leaves the at least one feedback outlet, to form a pulsating jet at the exit port.
In one embodiment, the present invention provides a method for manufacture of an apparatus for creating pulsating fluid flow, including forming a flowpath for creating pulsating fluid flow on a mandrel to create a fluidic oscillator insert, forming a housing for the fluidic oscillator insert, and inserting the fluidic oscillator insert into the housing to form the apparatus for creating pulsating fluid flow.
The features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the embodiments that follows.
A more complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, wherein:
While the present invention is susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
The present invention relates to improved apparatuses and improved methods for creating pulsating fluid flow and methods for manufacture of those apparatuses; more specifically, the present invention relates to improved apparatuses and improved methods for expelling pulses of fluid sequentially from different ports in a repeated cycle and methods for manufacture of those apparatuses.
In certain exemplary embodiments, after the fluid enters fluidic oscillator insert 300 through fluid flowline 400, fluidic oscillator insert 300 directs the fluid into interior flowline 401 and then into inlet 302, as shown in
The fluid forms a jet as it streams from inlet 302 into chamber 303 of the certain exemplary embodiment shown in
The pulsating action of the fluid flow generated by exemplary embodiments of the present invention arises from switches in the flow from along outwardly-projecting sidewall 304 to along outwardly-projecting sidewall 304′, and vice versa. At least two feedback passages 307 and 307′ are disposed on opposite sides of chamber 303 to help achieve these switches. Two opposed entrances 308 and 308′ to the feedback passages 307 and 307′ leave from the downstream end 306 of chamber 303. Two opposed exits 309 and 309′ to the feedback passages 307 and 307′ join the upstream end 305 of chamber 303. To continue with the example of the previous paragraph, a portion of the fluid will reach opposed entrance 308 and be directed into feedback passage 307 once it has traveled along sidewall 304. Of the portion of fluid that enters feedback passage 307, a smaller portion of the fluid will exit the fluidic oscillator insert 300 through feedback outlet 311, discussed later in more detail. The rest of the fluid that enters feedback passage 307, however, will be directed to opposed exit 309 and back into chamber 303. The entry of this fluid into chamber 303 disturbs the path of the jet of fluid issuing from inlet 302 such that the jet no longer adheres to outwardly-projecting sidewall 304. The jet of fluid will instead adhere to outwardly-projecting sidewall 304′ in the same manner as it adhered to outwardly-projecting sidewall 304.
The jet of fluid will then travel along the surface of outwardly-projecting sidewall 304′, and a portion of the fluid will enter opposed entrance 308′. This portion of the fluid will be directed into feedback passage 307′. Another portion of the fluid will be diverted from feedback passage 307′ into feedback outlet 311′, to be discussed later in more detail. The rest of the fluid entering feedback passage 307′ will continue to opposed exit 309′ and enter chamber 303. As with the fluid entering chamber 303 from opposed exit 309, the fluid leaving opposed exit to feedback passage 309′ will disturb the flow of fluid along the surface of outwardly-projecting sidewall 304′. The fluid path will switch from traveling along outwardly-projecting sidewall 304′ to traveling along outwardly-projecting sidewall 304, and the cycle will repeat.
At any time when the fluid flows along outwardly-projecting sidewall 304 and through feedback passage 307, no fluid flows along outwardly-projecting sidewall 304′ and through feedback passage 307′. The converse is also true. This oscillation of fluid from one half of the fluidic oscillator insert 300 to the other helps create the desired pulsating fluid flow. In particular, as fluid travels through either feedback passage 307 or 307′, a portion of the fluid will be drawn off by feedback outlet 311 or 311′, respectively. Fluid entering feedback outlets 311 and 311′ will be directed outside fluidic oscillator insert 300 into housing 200 and exit the apparatus through either exit flowline 201 or 201′, respectively. The effect of the flow oscillation between outwardly-projecting sidewalls 304 and 304′ and through feedback passages 307 and 307′ is that fluid will exit from only one feedback outlet 311 or 311′ at a given point in time. The fluid will travel from feedback outlets 311 or 311′ through exit flowlines 201 or 201′, respectively. Once the fluid has reached the end of exit flowlines 201 and 201′, the fluidic oscillator insert 300 will emit pulses of fluid through exit ports 202 and 202′ in succession.
Feedback cavity 310, disposed at the downstream end 306 of chamber 303, further promotes the oscillation of fluid flow in fluidic oscillator insert 300. While a portion of the fluid traveling along outwardly-projecting sidewalls 304 and 304′ is directed into the opposed entrances to the feedback passages 308 and 308′, the remainder of the fluid exits chamber 303 into feedback cavity 310. If the fluid enters feedback cavity 310 after traveling along outwardly-projecting sidewall 304, it follows a clockwise path around feedback cavity sidewall 312 and returns to chamber 303 near outwardly-projecting sidewall 304′. This fluid flow near outwardly-projecting sidewall 304′ destabilizes the fluid flow along outwardly-projecting sidewall 304. This added instability amplifies the oscillation effect produced by feedback passages 308 by drawing fluid to outwardly-projecting sidewall 304′ from outwardly-projecting sidewall 304. The cycle then reverses, with fluid entering from along outwardly-projecting sidewall 304′ and following a counterclockwise path in feedback cavity 310 to near outwardly-projecting sidewall 304. In certain embodiments, as shown in the top half of
Feedback outlets 311 and 311′ and exit flowlines 201 and 201′ may take any number of different paths that meet the requirements of specific applications, including paths that diverge from the plane of flowpath 301 shown in
In an exemplary embodiment, the exit flowlines may be entirely substantially perpendicular to the flow of fluid into the inlet, as illustrated by exit flowline 201′ shown in the bottom half of
In another exemplary embodiment shown in the top half of
In an exemplary embodiment, the exit flowlines are positioned at an angle to the flow of fluid into the inlet. This angle may be calibrated to achieve the goals of a particular application. For example, an operator using the present invention to clean a fluid flowline may find that a jet that hits the interior surface of the fluid flowline obliquely cleans better than a jet that hits the interior surface at a right angle. The optimal angle between the jet and the fluid flowline will depend on the material that needs to be removed from the interior surface of the fluid flowline. The optimal angle for removing softer material will generally be shallower than the optimal angle for removing harder materials. For example, the material in the fluid flowline may have a structure that requires a jet of fluid hitting it at a 45-degree angle in order for it to be removed. If the exit flowline is properly aligned, the fluid will hit the interior surface of the fluid flowline to be cleaned at a 45-degree angle. The angle chosen is not limited to 45 degrees but instead may be any angle best suited to the task for which the apparatus will be used. The erosion rate for a given material, ε, depends on the jet angle α according to the following equation: ε=A sinβα(cos α−μsin α), when β is a material property, μ is the coefficient of friction for the material, and A is a factor that does not depend on the angle. The optimal erosion rate will depend on the relationship between the material parameters captured β and μ. Fluid pulses at angle of about 15 degrees to about 30 degrees best erode natural rubber, fluid pulses at an angle of about 20 degrees to about 40 degrees best erode styrene-butadiene, fluid pulses at an angle of about 30 degrees to about 45 degrees best erode carbon steel, and fluid pulses of about 90 degrees will best erode ceramics.
The angle chosen need not be limited to the plane of the flowpath.
In certain exemplary embodiments, a fluid outlet 313 extends from feedback cavity 310, as shown in the top half of
In certain embodiments of the present invention, the apparatus for creating pulsating fluid flow may be constructed using the following method. A fluidic oscillator insert, such as the fluidic oscillator insert 100 shown in
In an exemplary embodiment of the manufacturing method, a flowpath such as flowpath 301 shown in
In certain exemplary embodiments, multiple flowpaths may be created in the fluidic oscillator insert. For example, in an exemplary embodiment, two opposed flowpaths are created in a single fluidic oscillator insert. These two opposed flowpaths may share the same flowline. On the other hand, in certain embodiments, portions of the two flowpaths may be shared, such as the exit flowlines. The two opposed flowpaths be similarly configured or alternatively, exhibit different configurations. In an exemplary embodiment, the exit ports of one flowpath may be located alongside the feedback passages of that flowpath as shown in the bottom half of
In exemplary embodiments of the present invention, the fluidic oscillator insert created from the mandrel must be enclosed by a housing such as housing 200 shown in
The housing may be joined to the fluidic oscillator insert using methods readily apparent to persons ordinarily skilled in the art having the benefit of this disclosure. In certain exemplary embodiments, the fluidic oscillator insert may be press fit into the housing such that friction holds the fluidic oscillator insert and the housing together. In other exemplary embodiments, the fluidic oscillator insert may be welded, cemented or joined with one or more threaded members to the housing. In addition, in certain exemplary embodiments, the fluid flowline 400 connects to housing 200, fluidic oscillator insert 300 or both, as shown generally in
In certain exemplary embodiments, additional fluidic oscillator inserts may be disposed downstream from fluidic oscillator insert 300, as shown in
In an alternative exemplary embodiment, the flowpath may be created in a half mandrel having a flat surface along a longitudinal axis of the half mandrel.
Interior flowline 401 directs the fluid through inlet 802. Inlet 802 is disposed between two opposed cusps 803 and 803′ that protrude into an oscillation cavity 804. Inlet 802 ejects the fluid as a jet into oscillation cavity 804. Oscillation cavity 804 is defined by a concave rear wall 805. Two opposed exit flowlines 806 and 806′ leave the oscillation cavity 804 near inlet 802 and cusps 803 and 803′. These two opposed exit flowlines 806 and 806′ curve such that a portion of the opposed exit flowlines 806 and 806′ is substantially perpendicular to the flow of fluid into inlet 802. Each of the two opposed exit flowlines 806 and 806′ has an exit port 807 and 807′, respectively.
Upon leaving inlet 802, the jet passes through oscillation cavity 804 to concave rear wall 805. At concave rear wall 805, the jet divides into two flows of fluid. A first flow of fluid will travel along concave rear wall 805 to the top half of the oscillation cavity 804 as it is depicted in
While these two flows will initially be symmetrical, their motion is inherently unstable. Inevitably, a small aberration in the fluid flow or apparatus will disturb the fluid flow such that the jet is pushed slightly to one side of oscillation cavity 804. This disturbance will cause the rotating flows to become asymmetrical. The rotating flows will force the jet to oscillate from the top of the oscillation cavity 804 to the bottom of oscillation cavity 804 as it is depicted in
The fluid will oscillate in fluidic oscillator insert 900 in much the same manner as the fluid oscillates in fluidic oscillator insert 300, illustrated in
While a portion of the fluid is diverted through the feedback passages 907 and 907′, the rest of the fluid will enter exit flowline 910 and 910′, respectively. For example, part of the fluid traveling along outwardly-projecting sidewall 904 will be partially diverted into feedback passage 907. The rest of the fluid will travel through exit flowline 910 and exit the fluidic oscillator insert 900 through exit port 912. Fluid traveling along outwardly-projecting sidewall 904′ will be partially diverted into feedback passage 907′. The rest of the fluid will travel through exit flowline 910′ and exit the fluidic oscillator insert 900 through exit port 912′. As the fluid oscillates between outwardly-projecting sidewalls 904 and 904′, exit ports 912 and 912′ will emit fluid pulses in succession.
Because fluid flowlines 910 and 910′ diverge, fluidic oscillator insert 900 discharges fluid at an angle from the flow of fluid into the inlet. As a result, fluidic oscillator insert 900 can be used in applications requiring pulses that precede the apparatus but are located to the sides of the apparatus. To cite just one example, these pulses may be useful in cleaning fluid flowlines or well bores. As discussed earlier in the disclosure, the exit angle can be tailored to maximize the clearing rate for a particular fluid flowline. In certain embodiments, the angle α from the flow of fluid into the inlet will be in the range of approximately 10 degrees to approximately 60 degrees. In certain embodiments, the angle from the flow of fluid into the inlet will be in the range of approximately 20 degrees to approximately 45 degrees. Further, the “x” shown in
Therefore, the present invention is well-adapted to carry out the objects and attain the ends and advantages mentioned, as well as those that are inherent therein. While the invention has been depicted, described, and is defined by reference to the exemplary embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only and are not exhaustive of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
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