Systems and methods to separate particles in fluids

Abstract

SYSTEMS AND METHODS FOR SEPARATING PARTICLES IN FLUIDS. These are separation elements that include microfluidic channels that can use a hydrodynamic separator or a flow routing element to separate particles in fluids. Particle sensors can be used to count particles in each microfluidic channel. A unique orifice pattern can be used to facilitate the use of a shared particle sensor for multiple microfluidic channels. Separation elements can be used in various systems such as engine fuel systems, bulk fuel systems, hydraulic particulate filters, and hydraulic deaeration intensifiers.

Description

1 / 78 “SYSTEMS AND METHODS FOR SEPARATING PARTICLES IN FLUIDS”

[001] This application claims the benefit of U.S. Provisional Application No. 62 / 942009, filed November 29, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[002] The present disclosure relates to the separation of particles. In particular, the present disclosure relates to the separation of particles in fluids.

[003] Particles dispersed in fluid can be problematic in certain systems, such as engine fuel systems, bulk fuel systems, hydraulic systems, or other systems for handling or storing fluids. For example, water particles (or water droplets) in fuel can be problematic in engine fuel systems of internal combustion engines. Water in fuel can damage fuel injectors due to corrosion or vaporization during combustion. Damage to injectors can cause various problems in engine operation, such as failure to meet jurisdictional emission standards. Damage to the fuel injector may require repairs or maintenance. Reduced operating time can be particularly costly for commercial or industrial vehicles.In general, the presence of gaseous, liquid, or solid particles dispersed in fluid can cause complications in various fluid systems, such as bulk fuel systems, hydraulic systems, etc. Traditional fluid filters capture particles in a medium structure. The medium structure can become clogged over time, requiring maintenance or replacement of the filter. SUMMARY

[004] The techniques of this disclosure generally refer to the orientation of certain particles in fluid within various fluid systems and the separation of these particles from the fluid or from particles of other sizes. In general, fluid systems may include particle separation elements, such as hydrodynamic separation elements, Petition 870230102574, dated 11 / 22 / 2023, page 9 / 110 2 / 78 to guide particles within a specific size range. The particle separation element may include an inlet and an outlet that has at least two flow branches. Particles within the specific size range may be guided to one of the two flow branches. In some embodiments, particles exceeding a limiting size range are guided to one of the two flow branches. Any remaining particles may flow through at least two flow branches. In some embodiments, the particle separation element may be used to supplement or replace a fluid filter.

[005] In one aspect, the present disclosure relates to a hydrodynamic separator. A system includes a hydrodynamic separation element having one or more hydrodynamic separators, each defining a curved microfluidic channel in fluid communication. Each microfluidic channel defines an inlet configured to receive a fluid and particles dispersed in the fluid, the particles having a composition different from the fluid, and an outlet that includes a first flow branch and a second flow branch. At a predetermined flow rate, each microfluidic channel is configured to direct any particles exceeding a corresponding size limit to the second flow branch and any remaining particles to either the first or second flow branch.The system also includes a particle sensor positioned along one or more hydrodynamic separators configured to provide signal data representing a signal corresponding to the fluid and the particles in the fluid. The system further includes a controller operationally coupled to the particle sensor to receive the signal data and operationally coupled to a fluid pump in fluid communication with the hydrodynamic separation element. The controller is configured to: control the fluid pump to direct fluid through the separation element. Petition 870230102574, dated 11 / 22 / 2023, page 10 / 110 3 / 78 hydrodynamics, determine if a limit level of particles is present in at least one microfluidic channel based on signal data from the particle sensor and control a flow rate through the hydrodynamic separation element in response to the determination that the limit level of particles is present in at least one microfluidic channel, to direct fluid at the predetermined flow rate through the hydrodynamic separation element to guide any particles exceeding the corresponding limit size to the second flow branch of at least one microfluidic channel.

[006] In another aspect, the present disclosure relates to a particle diverter. A system includes a particle separation element. The particle separation element includes one or more microfluidic channels in parallel fluid communication. Each microfluidic channel defines an inlet configured to receive a fluid and particles dispersed in the fluid, the particles having a composition different from the fluid, and an outlet that includes a first flow branch and a second flow branch. The system also includes a flow routing element positioned along at least one flow branch of at least one outlet. The system further includes a particle sensor positioned along one or more microfluidic channels configured to provide signal data representing a signal corresponding to the fluid and the particles dispersed in the fluid.The system includes a controller operationally coupled to at least one flow routing element and operationally coupled to the particle sensor to receive signal data. The controller is configured to: control the flow routing element to direct fluid flow to the first flow branch of at least one outlet of at least one microfluidic channel; determine if a threshold particle level is present in at least one microfluidic channel based on signal data from the particle sensor; and control the flow routing element in response to the determination that the threshold level is present. Petition 870230102574, dated 11 / 22 / 2023, page 11 / 110 4 / 78 The particle limit level is present in at least one microfluidic channel, to direct the fluid flow to the second flow branch of at least one microfluidic channel.

[007] In another aspect, the present disclosure relates to a particle classifier. A system includes a hydrodynamic separation element having a plurality of hydrodynamic separators in series fluid communication that includes at least one first hydrodynamic separator and a second hydrodynamic separator, each defining a curved microfluidic separation channel to separate particles of different size ranges. Each microfluidic separation channel defines an inlet configured to receive a fluid containing particles and an outlet that includes a first flow branch and a second flow branch.At a specific flow rate, each microfluidic separation channel is configured to direct any particles exceeding a corresponding size limit to the second flow branch and any remaining particles to either the first or second flow branch, with the first flow branch of the first hydrodynamic separator being in fluid communication with the inlet of the second hydrodynamic separator. The system also includes a microfluidic collection element in fluid communication with the hydrodynamic separation element. The microfluidic collection element includes a plurality of microfluidic collection channels, each in fluid communication with a different flow branch of the hydrodynamic separation element.The plurality of microfluidic collection channels includes at least: a first microfluidic collection channel in fluid communication with the second flow branch of the first hydrodynamic separator to receive any particles exceeding a first size limit, and a second microfluidic collection channel in fluid communication with the second flow branch of the second hydrodynamic separator to... Petition 870230102574, dated 11 / 22 / 2023, page 12 / 110 5 / 78 receive any particles that exceed a second size limit, where the first size limit is larger than the second size limit.

[008] In yet another aspect, the present disclosure relates to orifice patterns. A system includes a plurality of microfluidic capture channels, each configured to receive a flow of a fluid and particles dispersed in the fluid. The particles have a different composition from the fluid. The system also includes a light source configured to direct a beam of light in a frequency band along a path through the plurality of microfluidic capture channels. The frequency band is selected so as to have an absorbance by the particles different from the absorbance by the fluid. The system further includes an aperture element that defines a plurality of light apertures, each having a different set of light apertures aligned with each microfluidic capture channel. Each set of light apertures defines a unique spacing pattern along the corresponding microfluidic capture channel.The system also includes a light detector positioned to receive the light beam in a capture area after it has passed through the plurality of light apertures of the aperture element and through the plurality of microfluidic capture channels. The light detector is configured to provide a signal representing a quantity of light in the frequency band that remains after passing through the plurality of microfluidic capture channels. Additionally, the system includes a controller operationally coupled to the light detector and configured to: determine signal data based on the signal from the light detector, determine if a particle has passed through the capture area based on the signal data, and determine the unique spacing pattern associated with the particle that passed through the capture area based on the signal data. Petition 870230102574, dated 11 / 22 / 2023, page 13 / 110 6 / 78

[009] In yet another aspect, the present disclosure relates to the detection of water droplets. A system includes the system according to the present development, and the particles include a second fluid different from the fluid.

[010] In a further aspect, the present disclosure relates to an engine fuel system. A system includes a fuel line configured to distribute fuel to a fuel injector system. The system also includes a hydrodynamic separation element that has one or more hydrodynamic separators, each defining a curved microfluidic channel to separate particles in the fuel. Each microfluidic channel defines an inlet in fluid communication with the fuel line to receive fuel and an outlet that includes a first flow branch in fluid communication with the fuel line to supply fuel to the fuel injector system and a second flow branch to receive particles in a specific size range.

[011] In another aspect, the present disclosure relates to a bulk fuel system. A system includes a fuel line configured to distribute fuel from a bulk fuel storage tank to a vehicle fuel tank. The system also includes a hydrodynamic separation element that has one or more hydrodynamic separators, each defining a curved microfluidic channel to separate particles in the fuel. Each microfluidic channel defines an inlet in fluid communication with the fuel line to receive fuel and an outlet that includes a first flow branch in fluid communication with the fuel line to supply fuel to the vehicle fuel tank and a second flow branch to receive particles in a specific size range.

[012] In yet another aspect, the present disclosure relates to a hydraulic particulate filter. One system includes a hydraulic fluid line configured to Petition 870230102574, dated 11 / 22 / 2023, page 14 / 110 7 / 78 Distribute hydraulic fluid from a hydraulic pump to a hydraulic component. The system also includes a hydrodynamic separation element that has one or more hydrodynamic separators, each defining a curved microfluidic channel to separate particles in the hydraulic fluid. Each microfluidic channel defines an inlet in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump and an outlet that includes a first flow branch in fluid communication with the hydraulic fluid line to supply hydraulic fluid to the hydraulic component and a second flow branch to receive particles within a specific size range.

[013] In yet another aspect, the present disclosure relates to the intensification of hydraulic deaeration. A system includes a hydraulic fluid return line configured to distribute hydraulic fluid from a hydraulic component to a hydraulic pump. The system also includes a hydrodynamic separation element that has one or more hydrodynamic separators, each defining a curved microfluidic channel to separate particles in the hydraulic fluid. Each microfluidic channel defines an inlet in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump and an outlet that includes a first flow branch in fluid communication with the hydraulic fluid line to supply hydraulic fluid to the hydraulic pump and a second flow branch to receive particles in a specific size range. BRIEF DESCRIPTION OF THE DRAWINGS

[014] Several modes of revelation are illustrated in the drawings, which are summarized as follows: Figure 1 is a conceptual diagram showing an example of a fluid system that includes a particle separation element configured to receive Petition 870230102574, dated 11 / 22 / 2023, page 15 / 110 8 / 78 a fluid flow originating from a fluid source according to the present disclosure. Figure 2 is a conceptual diagram showing an example of a fluid system that can be used to handle fuel in the machine, usable with the particle separation element of Figure 1. Figure 3 is a conceptual diagram showing an example of a fluid system that can be used to handle bulk fuel usable with the particle separation element of Figure 1. Figure 4 is a conceptual diagram showing an example of a fluid system that can be used to distribute usable hydraulic fluid with the particle separation element of Figure 1. Figure 5 is a conceptual diagram showing an example of a fluid system that can be used to deaerate hydraulic fluid, usable with the particle separation element of Figure 1. Figure 6 is a conceptual diagram showing an example of an optical or light-based particle sensor that could be used with the particle sensor in Figure 1. Figure 7 is a conceptual diagram showing an example of an arrangement for using the particle sensor from Figure 1 in relation to a microfluidic channel. Figure 8 is a conceptual diagram showing another example of an arrangement for using the particle sensor from Figure 1 in relation to a microfluidic channel. Figures 9-10 are conceptual diagrams that show another arrangement for using the particle sensor from Figure 1 with a particle separation element and a microfluidic capture element. Petition 870230102574, dated 11 / 22 / 2023, page 16 / 110 9 / 78 Figures 11A-B are conceptual diagrams that show an example of a technique for counting the number of particles in multiple microfluidic channels using a shared light detector usable with the particle sensor of Figure 1. Figure 12 is a conceptual diagram showing an example of a fluid system that can be used to remove particles, usable with the particle separation element of Figure 1. Figures 13A-D are images and plots that show the hydrodynamic separator device and pixel intensity versus channel position, respectively. Figure 14 is a conceptual diagram showing relative angle positions around a hydrodynamic separator device from Figures 13A-D. Figure 15 is a plot showing the oriented percentage versus the channel length for a hydrodynamic separator device from Figures 13AD. DETAILED DESCRIPTION

[015] In the detailed description that follows, reference is made to several specific modalities. It should be understood that other modalities are contemplated and can be performed without departing from the scope or spirit of the present revelation. The detailed description that follows, therefore, should not be considered in a limiting sense.

[016] This disclosure provides techniques for guiding certain particles in fluid in various fluid systems and for separating those particles from the fluid or from particles of other sizes. In general, fluid systems may include particle separation elements, such as hydrodynamic separation elements, to guide particles within a specific size range. The particle separation element may include an inlet and an outlet that has at least two Petition 870230102574, dated 11 / 22 / 2023, page 17 / 110 10 / 78 flow branches. Particles within a specific size range can be directed to one of the two flow branches. In some embodiments, particles exceeding a limiting size range are directed to one of the two flow branches. Any remaining particles can flow through at least two flow branches. In some embodiments, the particle separation element can be used to supplement or replace a fluid filter.

[017] Particle separation elements, which may include hydrodynamic separation elements, can be used as filter replacements or complements. In particular, particle separation elements can be used to concentrate particles above a critical size in a portion of a fluid stream. This portion of the fluid stream can be removed from the system, thus removing most of the particles exceeding a limit size. In some cases, this can replace part or all of the functionality of a filter. The performance of particle separation elements may not change over time and may not require regular replacement. In some embodiments, a filter can be used downstream of the particle separation element to remove particles below the limit size. Additionally, in some embodiments, the particles guided by the particle separation element are filtered out.This can be done at a lower nominal speed than a system without a particle separation element, thus leading to a lower pressure drop in the filter and a longer filter lifespan.

[018] Particle separation elements, which may include hydrodynamic separation elements, can also be used to classify particles of different sizes. In some applications, a size limit may be determined. The particle separation element may be designed to concentrate particles above the size limit into a concentrated fluid portion of a fluid stream. The concentrated portion of the fluid stream may be removed from Petition 870230102574, dated 11 / 22 / 2023, page 18 / 110 11 / 78 system. This technique can be used to concentrate particles for particle counting. This technique can also be used to separate different types of particles or to concentrate certain materials for collection.

[019] A microfluidic particle sensor, or microfluidic capture element, can be used to detect individual contaminants in a fluid, such as a liquid stream. A separator or segmentation stage can be positioned upstream of the particle sensor. The segmentation stage, or particle separation element, can separate particles into different fluid stream paths based on particle size. This could be achieved, for example, with Dean flow separation. Once the particles are in stream paths based on their particle size, the stream paths are sent to different capture channels of a microfluidic capture element. The capture channels are associated with particle sensors that count the number of particles. Knowing the number of particles in each capture channel, an approximate particle size distribution can be determined.The sensor can be an optical sensor, a capacitance sensor, a magnetic sensor, or another type of sensor. Alternatively, the particle sensor may contain only a microfluidic channel and a sensor. The use of the microfluidic channel can increase sensitivity to individual contaminants compared to other techniques, such as Mie diffusion. Signal processing can also be used to identify the type of contaminant.

[020] Additionally, particle separation elements, which may include hydrodynamic separation elements, can be used for selective particle waste removal. In some cases, only particles above a certain size may be considered a target for removal from a system. Uses for selective particle waste removal may include, but are not limited to: removal or concentration of fats in milk (fats are typically Petition 870230102574, dated 11 / 22 / 2023, page 19 / 110 12 / 78 agglomerates from 0.1 to 15 micrometers), removal or concentration of orange juice pulp, removal of contaminants in semiconductor fluid processing, and removal of ink agglomerates in industrial ink processing. In an example related to fluid pastes for polishing tablets, particle separation elements can be designed to remove particles above a limit size, which may be agglomerates or impurities, while allowing the passage of particles below the limit size. Definitions Particle

[021] As used in this document, the term “particle” refers to a discrete quantity of material that can be dispersed in a different fluid. Non-limiting examples of material that can be formed particles include dirt, metal, air bubbles, and water droplets. In one specific example, water droplets can be dispersed in a hydrocarbon fluid, such as gasoline or diesel fuel, to form an emulsion. In another example, air bubbles can be dispersed in a hydraulic fluid. Upstream / downstream

[022] As used in this document, the term “downstream” refers to a direction along a fluid flow. The term “upstream” refers to the opposite of downstream, or a direction opposite to the fluid flow. Microfluidic channel

[023] As used in this document, the term “microfluidic channel” refers to a channel that has at least one dimension less than 1 millimeter (1000 micrometers). A microfluidic channel may have a channel width less than 1000 micrometers, a channel height (or depth) less than 1000 micrometers, or both. In some embodiments, for higher flow applications, at least one dimension of the microfluidic channel may be greater than 1 millimeter. In some Petition 870230102574, dated 11 / 22 / 2023, p. 20 / 110 13 / 78 modalities, at least one dimension of the microfluidic channel is greater than or equal to 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 millimeters or less than or equal to 10, 9, 8, 7, 6, 5, 4, 3, or 2 millimeters. In general, the channel can have any length suitable to provide an adequate pressure drop balanced with adequate particle orientation.

[024] Microfluidic channels can be described by a cross-sectional area, width x height. In some embodiments, the cross-sectional area of ​​the microfluidic channel can be less than 10, 9, 8, 7, 6, 5, 4, 3, or 2 square millimeters.

[025] Microfluidic channels can also be described by a hydraulic diameter. For a microfluidic channel that has a rectangular cross-section, for example, the hydraulic diameter can be calculated as follows: Dh = 2 x height x width / height + width (Equation 1) where Dh is the hydraulic diameter. Other cross-sectional shapes can be calculated according to techniques known by a person of common skill in the art, having the benefit of this revelation. In some modalities, the hydraulic diameter of the microfluidic channel may be less than 5, 4, 3, 2, or 1 millimeter. In at least one modality, the hydraulic diameter of the microfluidic channel may be less than 1 millimeter. Hydrodynamic separator

[026] As used in this document, the term “hydrodynamic separator” refers to a curved fluid channel that includes at least one inlet to receive a fluid flow and an outlet that includes at least two branches to divide the fluid flow. The fluid channel may be a microfluidic channel. The inlet may receive a fluid that may contain particles of various sizes. At a specific flow rate, the hydrodynamic separator is configured to orient any particles exceeding a size limit to one of the branches. Any remaining particles are not oriented into the fluid flow. Petition 870230102574, dated 11 / 22 / 2023, page 21 / 110 The remaining 14 / 78 particles can be divided among all branches, for example, based on volume fractions or outflow rate ratios associated with each branch. Hydrodynamic separators can be designed based on at least one or more of the following parameters: a Dean number, a Reynolds number, a hydraulic diameter, a radius of curvature, a target flow rate, a target pressure drop, a critical particle size, a fluid viscosity, an operating temperature (which can affect fluid viscosity), an outflow rate ratio, or any combination thereof. Hydrodynamic separators can also be described as Dean flow separators.

[027] In general, hydrodynamic separators include curved microfluidic channels designed to orient particles exceeding a size limit toward the inner wall of the curve. The cross-sectional area of ​​the microfluidic channel limits the maximum particle size that can enter the microfluidic channel. The device defines a geometry (such as width, height, radius of curvature, and channel length) designed to orient particles in a known fluid at a specific flow rate or flow rate range. Particles oriented near the inner wall can then be removed from the system by removing a portion of the fluid near the inner wall. In other embodiments, depending on the device geometry and operating conditions, particles and waste stream may alternatively be oriented near the outer wall.The device design may depend on the application flow rate, fluid properties (such as viscosity and density), and the particle size limit. The hydrodynamic separator can act as a filter or as a pre-filter in a system.

[028] Curved microfluidic channels can be used to guide particles of a predetermined size under suitable flow conditions. In a curved channel or tube under laminar flow conditions, the fluid inertia creates a pressure gradient across the channel. To relieve the pressure gradient, two spiral flows Petition 870230102574, dated 11 / 22 / 2023, page 22 / 110 15 / 78 known as Dean flows (sometimes called secondary flows) can form. Dean flow can exhibit resistance to forward movement over any particles in the fluid. In larger channels, particles can be dragged along the channel in a spiral motion. When channels become smaller, as in microfluidic channels, Dean flow can be balanced with two additional forces, so that particles can become trapped and oriented on the inner wall of the curved channel. These forces can be described as the shear-induced lift force, which causes a lifting force towards the wall, and as the wall-induced lift force, which pushes the particle in the opposite direction to the wall due to the limitation of fluid flow as the particle approaches the wall. Particles can be oriented to a specific stream path in the curved channel.The orientation of particles in this manner can be called hydrodynamic separation or Dean flow separation. Flow routing element

[029] As used in this document, a “flow routing element” refers to a component configured to allow selective routing of a fluid flow leaving a fluid channel. Non-limiting examples of flow routing element components include a valve or a solenoid. In one example, a flow routing element might include one or more valves configured to divert flow to one or more branches in any suitable manner. Dean's number

[030] Dean's number describes the behavior of fluids in a curved tube and considers inertial forces, centripetal forces, and viscous forces acting on the fluid. In various embodiments, the system is configured to have a Dean number between 5 and 25. Dean's number is defined as follows: De = Re J^L· (Equation 2) Petition 870230102574, dated 11 / 22 / 2023, p. 23 / 110 16 / 78 where Re is the Reynolds number and Rc is the radius of curvature of the fluid channel. Reynolds number

[031] The Reynolds number describes the ratio between inertial forces and viscous forces and is defined as follows: Re = ^-(Equation 3) where ρ is the fluid density, U is the average fluid velocity, and μ is the dynamic viscosity of the fluid.

[032] Reference will now be made to the drawings, which represent one or more aspects described in this disclosure. However, it will be understood that other aspects not represented in the drawings are covered by the scope of this disclosure. Similar numbers used in the figures refer to similar components, steps, and the like. However, it will be understood that the use of a reference character to refer to an element in a given figure is not intended to limit the element in another figure identified with the same reference character. Furthermore, the use of different reference characters to refer to elements in different figures is not intended to indicate that the differently referenced elements cannot be the same or similar.

[033] Figure 1 is a conceptual diagram showing an example of a fluid system 100 that includes a particle separation element 102 configured to receive a fluid stream from a fluid source 104. The fluid system 100 can be any suitable type of system that can benefit from the use of the particle separation element 102, such as an engine fuel system, a bulk fuel system, or a hydraulic system. The fluid source 104 can be configured to contain a fluid that may contain particles. The particle separation element 102 can be used as a filter to facilitate the removal of particles, within a specific size range, from the fluid. Petition 870230102574, dated 11 / 22 / 2023, page 24 / 110 17 / 78 For example, particles considered contaminants or waste can be removed. Additionally or alternatively, the particle separation element 102 can be used to facilitate the classification of particles of different sizes. The classification of particles of different sizes can allow the fluid system 100 to determine how many particles are in different size ranges.

[034] The particle separation element 102 can be fluidly coupled between the fluid source 104 and a fluid destination, such as the optional fluid destinations 106, 108. The particle separation element 102 can be positioned downstream of the fluid source 104. The particle separation element 102 can be positioned upstream of the fluid destinations 106, 108. The fluid destination 106 can be a component of the fluid system 100 that stores, uses, or consumes the fluid, such as fuel to be consumed by an engine. The fluid destination 108 can be a component of the fluid system 100 that uses the fluid and returns the fluid to the fluid source 104, such as hydraulic fluid used in a hydraulic piston. The particle separation element 102 can remove particles, within a specific size range, from the fluid before supplying the fluid to one of the fluid destinations 106, 108.

[035] The particle separation element 102 may include any suitable components usable for removing particles or classifying particles in the fluid. In some embodiments, the particle separation element 102 includes a hydrodynamic separation element. In general, the particle separation element 102, which may include the hydrodynamic separation element, may not become loaded with particles and may not change performance over time or require regular replacement.

[036] The hydrodynamic separation element may include one or more hydrodynamic separators. In some embodiments, the hydrodynamic separators are arranged in parallel. The channel length and arrangement Petition 870230102574, dated 11 / 22 / 2023, page 25 / 110 18 / 78 hydrodynamic separators can be designed to provide target pressure drops.

[037] In some embodiments, the particle separation element 102 includes a flow routing element. The flow routing element may be disposed at the outlet of the particle separation element 102. The flow routing element may include one or more valves or solenoids to divert the fluid flow.

[038] In general, the particle separation element 102 includes an outlet that has at least two different branches. The fluid flow can be divided between the different branches. In some embodiments, with the use of the hydrodynamic separation element, all particles in the specific size range can be directed to one of the branches. Each branch can be associated with particles in different size ranges (see Figures 9-10).

[039] Each branch may be directed to a different fluid destination or be in fluid communication with the same. In some embodiments, one branch may be directed to fluid destination 106 and another branch may be directed to fluid destination 108.

[040] A fluid pump 114 can be used to control a fluid flow rate through the particle separation element 102. The fluid pump 114 can be positioned at any suitable location relative to the particle separation element 102 to facilitate flow rate control, such as upstream, downstream, or integrated into the particle separation element. In the illustrated embodiment, the fluid pump 114 is positioned upstream of the particle separation element 102.

[041] A particle sensor 112 can be used to detect any particles in the fluid stream. The particle sensor 112 can be positioned at any suitable location relative to the particle separation element 102 to Petition 870230102574, dated 11 / 22 / 2023, page 26 / 110 19 / 78 facilitate the detection of certain particles, such as upstream, downstream, or integrated into the particle separation element. In some embodiments, the particle sensor 112 may be positioned between the inlet and outlet of the particle separation element 102. The particle sensor 112 may use any type of mechanism suitable for detecting particles in the fluid. For example, the particle sensor 112 may include or be a light-based particle sensor 200 (FIGURE 6) or a capacitance-based sensor.

[042] A microfluidic pickup element 116 can be used to capture particles of different sizes from one or more of the branches of the particle separation element 102. The microfluidic pickup element 116 is shown positioned downstream of the particle separation element 102. In some embodiments, the microfluidic pickup element 116 can be described as forming part of the particle separation element 102. The microfluidic pickup element 116 may include one or more microfluidic pickup channels. In some embodiments, the microfluidic pickup channels are arranged in parallel. The channel length and arrangement of the microfluidic pickup channels can be designed to provide target pressure drops and particle orientation.

[043] Each microfluidic channel can be fluidly coupled to one of the branches of the particle separation element 102. The microfluidic capture element 116 can also include one or more particle sensors 112 to detect different sizes of particles that have been sorted by the particle separation element 102. The microfluidic capture element 116 can also be used to determine whether the particle separation element 102 has successfully removed some or all of the particles in a specific size range. The microfluidic capture element 116 can also include an element of Petition 870230102574, dated 11 / 22 / 2023, page 27 / 110 20 / 78 flow routing. The flow routing element can be used to facilitate the removal of particles within a specific size range.

[044] A fluid subsystem 120 can be defined that may include one or more of the following: the particle separation element 102, the fluid pump 114, the microfluidic capture element 116 and a controller 110. The controller 110 can be used to facilitate various functionalities of the fluid subsystem 120 described in this document.

[045] Various configurations of fluid system 100 are contemplated. Non-limiting examples of additional configurations and various components of fluid system 100 are shown and described in more detail in this document.

[046] In one example, which can be described as a kidney loop type filtration (not shown), the fluid pump 114 can be used to provide a fluid flow from the fluid source 104, or from the source reservoir, through the particle separation element 102, which may include a hydrodynamic separator element, which returns a main flow to the fluid source 104 through a filter. Industrial systems with liquid fluids can use kidney loop type filtration systems to remove particles. The particle separation element 102 can be used between the fluid pump 114 and the filter.The particle separation element 102 can provide a main outlet flow to the fluid source 104 and return a secondary outlet flow containing certain particles to the filter, which can concentrate particles and minimize the volume of fluid that needs to be filtered, as well as reduce the nominal velocity, which can decrease the pressure drop in the filter.

[047] One or more of the components, such as controllers, sensors, detectors, or systems, described in this document may include a processor, such as a central processing unit (CPU), computer, Petition 870230102574, dated 11 / 22 / 2023, page 28 / 110 21 / 78 Logical arrangement or other device capable of directing data arriving at or leaving the component. The processor may include one or more computing devices that have memory, processing, and communication hardware. The processor may include a set of circuits used to couple various controller components to each other or to other components operationally coupled to the controller. Processor functions may be performed by hardware and / or as computer instructions on a computer-readable, non-transient storage medium.

[048] The processor may include any one or more of a microprocessor, a microcontroller, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), and / or an equivalent set of distinct or integrated logic circuits. In some examples, the processor may include multiple components, such as any combination of one or more microprocessors, one or more controllers, one or more DSPs, one or more ASICs, and / or one or more FPGAs, as well as another set of distinct or integrated logic circuits. The functions assigned to the processor in this document may be incorporated as software, firmware, hardware, or any combination thereof.

[049] In one or more embodiments, the processor functionality may be implemented using one or more computer programs with the use of a computing device, which may include one or more processors and / or memories. The code and / or program logic described herein may be applied to the input data / information to perform the functionality described herein and generate the desired output data / information. The output data / information may be applied as an input to one or more other devices and / or methods as described herein, or as would be applied in a known manner. In view of the above, it will be Petition 870230102574, dated 11 / 22 / 2023, page 29 / 110 22 / 78 It is readily apparent that the functionality of the controller as described herein can be implemented in any manner known to one skilled in the art.

[050] Figure 2 is a conceptual diagram showing an example of a fluid system that can be used to handle fuel in the machine using the particle separation element 102. The particle separation element 102, which may include a hydrodynamic separator element, can be used in a fluid system 120, such as an engine fuel system, and can replace the use of a primary filter along a main fuel line 122. In an engine fuel system, the lift pump pulls fluid from the fuel tank and pushes the fluid into the high-pressure common line. Some of the fuel can be returned from the fuel injector system to the fuel tank with a fuel return line 128.

[051] As illustrated, the fluid pump 114, such as a fuel pump or a lift pump, can be used to provide a fluid flow, such as fuel, from the fluid source 104, such as a fuel tank, through the particle separation element 102 via the main fuel line 122. The particle separation element 102 can provide a main outflow along the main fuel line 122 using a first flow branch 123 to the fluid destination 106, such as a fuel injector system, which may include a high-pressure common conduit, and return a secondary outflow containing certain particles to the fluid source 104 along a second flow branch 124. Non-limiting particle examples include dirt and water droplets.

[052] The particle separation element 102 can be positioned upstream or downstream of the pump for fluids 114. In the illustrated embodiment, the particle separation element 102 is positioned downstream of the pump for Petition 870230102574, dated 11 / 22 / 2023, page 30 / 110 23 / 78 fluids 114. A filter 126 may be positioned downstream of the particle separation element 102 along the main fuel line 122. The filter 126, or fuel filter, may be configured to filter gasoline or diesel fuel particles. The fluid system 120 may also include a fuel return line 128 from the fluid destination 106 to the fluid source 104. In other embodiments (not shown), the filter 126 may be positioned along, or another filter 126 may also be positioned along, the second flow branch 124, which may filter particles at a lower flow rate and pressure drop.

[053] The particle separation element 102 can be configured to remove particles that exceed, or are larger than, a specific limit size of the main fuel line diameter 122, while the fluid pump 114 supplies fuel at a specific flow rate for engine operation, and delivers these particles to the second flow branch 124. Examples of non-limiting specific size limits include 1, 2, 5, 10, 15 or 20 micrometers.

[054] The output of the particle separation element 102 can be described as having two output streams: a “clean” output stream along the first flow branch 123 to the main fuel line 122 and a “dirty” output stream along the second flow branch 124. The clean output stream may be predominantly free of particles above the limit size. The clean output stream may be sent to the filter 126 and ultimately to the fluid destination 106, shown as a common high-pressure conduit of a fuel injector system. The dirty output stream may contain most of the particles above the critical size. The dirty stream may be sent back to the fluid source 104, shown as a fuel tank. In other embodiments, the dirty output stream may be combined with the fuel return line from the common high-pressure conduit system.In other words, the second flow branch 124 can be fluidly coupled to the fuel return line 128. Petition 870230102574, dated 11 / 22 / 2023, page 31 / 110 24 / 78 before returning to the fluid source 104. The particle separation element 102 may have a mechanism to control the dirty outflow along the second flow branch 124, such as a valve (not shown), to facilitate operation as the pressure restriction in the filter increases over time due to the loading of the filter 126 along the first flow branch 123.

[055] Figure 3 is a conceptual diagram showing an example of a fluid system that can be used to handle bulk fuel using the particle separation element 102. The particle separation element 102, which may include a hydrodynamic separator element, can be used in a fluid system 140, such as a fuel dispensing station, and can be used to remove particles before delivering the fuel to the fluid destination 106, such as a vehicle.

[056] As illustrated, the fluid pump 114 can be used to provide a fluid flow, such as fuel, from the fluid source 104, such as a bulk fuel storage tank, through the particle separation element 102 to a main fuel line 142. The particle separation element 102 can provide a main outflow along the main fuel line 142 using a first flow branch 143 to the fluid destination 106, such as a vehicle, and a secondary outflow containing certain particles for return to the fluid source 104 along a second flow branch 144 or for sending to the fluid destination 108, such as a secondary storage tank. Non-limiting particle examples include dirt and water droplets.

[057] The particle separation element 102 can be positioned upstream or downstream of the fluid pump 114. In the illustrated embodiment, the particle separation element 102 is positioned downstream of the fluid pump 114. A filter 146 can be positioned downstream of the separation element. Petition 870230102574, dated 11 / 22 / 2023, page 32 / 110 25 / 78 particles 102 along the main fuel line 122. The filter 146, or fuel filter, can be configured to filter gasoline or diesel fuel particles. The fluid system 120 may also include a fuel return line 128 from the fluid destination 106 to the fluid source 104. In other embodiments (not shown), the filter 146 may be positioned along, or another filter 146 may also be positioned along, the second flow branch 144, which can filter particles at a lower flow rate and pressure drop.

[058] The particle separation element 102 can be configured to remove particles larger than a specific diameter limit size from the main fuel line 122, while the fluid pump 114 supplies fuel at a specific flow rate suitable for the fuel dispensing station, and delivers these particles to the second flow branch 144.

[059] The output of the particle separation element 102 can be described as having two output streams: a “clean” output stream along the first flow branch 143 to the main fuel line 142 and a “dirty” output stream along the second flow branch 144. The clean output stream may be predominantly free of particles above the limit size. The clean output stream may be sent to the filter 126 and ultimately to the fluid destination 106, shown as a common high-pressure system conduit. The dirty output stream may contain most of the particles above the critical size. The dirty output stream may be sent back to the fluid source 104, shown as a bulk fuel storage tank, or it may be sent to the fluid destination 108, shown as a separation tank to contain the dirty or contaminated fuel.The particle separation element 102 may have a mechanism for controlling the dirty outlet flow along the second flow branch 144, such as a valve (not shown), to facilitate operation as the... Petition 870230102574, dated 11 / 22 / 2023, page 33 / 110 26 / 78 pressure restriction in the filter increases over time due to filter loading 146 along the first flow branch 143.

[060] Figure 4 is a conceptual diagram showing an example of a fluid system that can be used to distribute hydraulic fluid using the particle separation element 102. The particle separation element 102, which may include hydrodynamic separator elements, can be used in a fluid system 160, such as a hydraulic cylinder system, and can be used to remove particles before supplying hydraulic fluid to hydraulic components, such as an actuating cylinder, to protect the hydraulic components from particles.

[061] As illustrated, the fluid pump 114, as a hydraulic pump, can be used to provide a fluid flow from the fluid source 104, such as a hydraulic fluid reservoir, through the particle separation element 102 to a main fluid line 162. The fluid source 104 may be in fluid communication with an inlet of the fluid pump 114. The particle separation element 102 may provide a main outlet flow along the main fluid line 162 using a first flow branch 163 to the fluid destination 106, such as a hydraulic component, which may include an actuator cylinder, and a secondary outlet flow containing certain particles for return to the fluid source 104 along a second flow branch 164. Non-limiting particle examples include dirt, air bubbles, or water droplets.The fluid system 160 may also include a fluid return line 168 from the fluid destination 106 to the fluid source 104. The second flow branch 164 may be fluidly coupled to the fluid return line 168 before returning to the fluid source 104.

[062] The particle separation element 102 can be positioned upstream or downstream of the fluid pump 114. In the illustrated embodiment, the Petition 870230102574, dated 11 / 22 / 2023, page 34 / 110 27 / 78 particle separation element 102 is positioned downstream of the fluid pump 114. A hydraulic fluid filter 166 may be positioned downstream of the particle separation element 102 along the second flow branch 164, the fluid return line 168, or both. As illustrated, the second flow branch 164 and the fluid return line 168 are combined before reaching the filter 166. The filter 166 may be in fluid communication with the fluid source 104.

[063] The output of the particle separation element 102 can be described as having two output streams: a “clean” output stream along the first flow branch 163 to the main fluid line 162 and a “dirty” output stream along the second flow branch 164. The clean output stream can continue to the fluid destination 106, shown as hydraulic components. The dirty output stream can be combined with the fluid return line 168, which would run through the filter 166 before returning to the fluid source 104, shown as a fluid reservoir. The particle separation element 102 can be designed to operate within the range of temperatures, flows and system configurations (e.g., extension of a hydraulic cylinder).

[064] Figure 5 is a conceptual diagram showing an example of a fluid system that can be used to deaerate hydraulic fluid using particle separation element 102. Particle separation element 102, which may include hydrodynamic separator elements, can be used in a fluid system 180, such as a hydraulic cylinder system, and can be used to remove nucleated air bubbles before returning the hydraulic fluid to the fluid source 104, such as a main hydraulic fluid reservoir, to protect the fluid destination 106, such as hydraulic components, against air bubbles.

[065] As illustrated, the fluid pump 114, as a hydraulic fluid pump, can be used to provide a fluid flow coming from Petition 870230102574, dated 11 / 22 / 2023, page 35 / 110 28 / 78 from fluid source 104, as a main hydraulic fluid reservoir, along a main fluid line 182 to fluid destination 106, as a hydraulic component, which may include an actuator cylinder. A fluid return flow may be provided from fluid destination 106 to a nucleation filter 169 to nucleate air bubbles in the fluid along the fluid return line 188. The particle separation element 102 may be positioned downstream of the nucleation filter 169. The nucleation filter 169 may be in fluid communication with an inlet of the particle separation element 102 and the fluid destination 106.The particle separation element 102 can provide a main outlet flow along the fluid return line 188 using a first flow branch 183 to the fluid source 104 and a secondary outlet flow containing certain particles to the fluid destination 108, such as a settling reservoir or an aerated oil collection volume, along a second flow branch 184. The fluid destination 108 may be in fluid communication with the fluid source 104 with restricted flow to allow the aerated hydraulic fluid to be collected and decanted.

[066] The fluid in a hydraulic fluid system 180 is pressurized by the fluid pump 114. The highly pressurized fluid can dissolve more air. When the fluid is depressurized in the fluid return line 188, the fluid can become supersaturated with air, which can lead to nucleation and formation of air bubbles in the fluid stream. The air bubbles can be removed before the fluid is captured by the fluid pump 114 again. Air bubbles reaching the fluid pump 114 can cause cavitation, which can be noisy and can damage the fluid pump. The nucleation filter 169 can be used for nucleation and growth of air bubbles. The air bubble-laden fluid can be sent through the particle separation element 102, which may include a hydrodynamic separator. Air bubbles can be concentrated in an "aerated oil return" outflow stream along the second flow branch 184. Petition 870230102574, dated 11 / 22 / 2023, page 36 / 110 29 / 78 aerated oil return outflow can be returned to fluid destination 108, or settling reservoir, in a volume that allows for natural settling of bubbles. Fluid destination 108 can be a separate compartment in the same container as fluid destination 106. The “main return” along the outflow, which has no air bubbles, is sent to fluid destination 106 along fluid return line 188 and can be immediately available for use by fluid system 180.

[067] Figure 6 is a conceptual diagram showing an example of an optical or light-based particle sensor 200 that can be used in or as part of the particle sensor 112 (Figure 1). In general, any suitable type of particle sensor can be used, including those described, for example, in PCT application No. PCT / US2019 / 034809, filed May 31, 2019, which is incorporated by reference. When the particle sensor 200 is used to detect fluid droplets, the particle sensor 200 can be described as a droplet sensor. The particle sensor 200 can be operationally coupled to the controller 110 and optically coupled to a microfluidic channel 201, which can be part of a hydrodynamic separator of the particle separation element 102 (Figure 1) or part of the microfluidic capture element 116 (Figure 1).

[068] As illustrated, the particle sensor 200 includes a light source 202, a light aperture 204 and a light detector 206. The controller 110 can be operationally connected to the light detector 206 and can also be operationally connected to the light source 202.

[069] The microfluidic channel 201 is configured to receive a flow of fluid 208. The microfluidic channel 201 can have any suitable cross-sectional shape, such as rectangular, circular, or oval. The particle sensor 200 can be configured to detect and characterize particles 210, such as liquid droplets, Petition 870230102574, dated 11 / 22 / 2023, page 37 / 110 30 / 78 air bubbles, dirt, metal, in the fluid flow 208 that can flow through the microfluidic channel 201.

[070] Particles 210 can be dispersed in fluid 208 in the microfluidic channel 201. For example, particles 210 can be suspended in fluid 208 in a separate phase or produced from a different composition or material. In other words, particles 210, which may be liquid, are not dissolved in fluid 208. In one example, particles 210 may include a fluid other than fluid 208.

[071] In general, the microfluidic channel 201 is sized to receive one or more of the particles 210 at a time. In some embodiments, the microfluidic channel 201 has a cross-sectional area sized to receive one particle 210 of a predetermined size at a time. In particular, the cross-sectional area of ​​the microfluidic channel 201 may be approximately the same size as a cross-sectional area of ​​the particle 210, which may facilitate the accounting of one particle 210 at a time to facilitate the accuracy of the particle 210 accounting and sizing.

[072] The cross-sectional area can be defined as orthogonal to the direction of fluid flow 208. In other words, the cross-sectional area can be described as transverse to a longitudinal fluid flow 208. The cross-sectional area can be defined as a channel height (or depth) multiplied by a channel width. Both the channel height and the channel width can be orthogonal to the direction of fluid flow 208. In some embodiments, the channel depth is less than or equal to the channel width. The use of a relatively shallow channel depth can prevent particles 210 from becoming trapped between the light source 202 and the light detector 206, or hidden behind each other, as the particles flow through the channel. Petition 870230102574, dated 11 / 22 / 2023, p. 38 / 110 31 / 78 microfluidic 201, which increases the opportunity for each particle to be detected. Light source

[073] In the illustrated embodiment, the light source 202 is positioned outside the microfluidic channel 201. At least one light aperture 204 is positioned between the light source 202 and the light detector 206. In some embodiments, the light aperture 204 is positioned before the microfluidic channel 201, for example, between the light source 202 and the microfluidic channel 201. In some embodiments, the light aperture 204 is positioned after the microfluidic channel 201, for example, between the microfluidic channel 201 and the light detector 206.

[074] The light source 202 is configured to direct light 212 through the light aperture 204 to form the light beam 214. The light beam 214 is directed to traverse the microfluidic channel 201. The light beam 214 may be collimated or substantially collimated by the light aperture 204, at least for the path length of the light beam 214 through the microfluidic channel 201. The light beam 214 may define a geometric axis that extends through the microfluidic channel 201. The walls of the microfluidic channel 201 may be formed of a translucent material, at least for the light 212 provided by the light source 202.

[075] The path of the light beam 214 crossing the microfluidic channel 201 defines the capture area 216, which can also be described as a capture volume, in which particles 210 can be detected. After the light beam 214 passes through the microfluidic channel 201, the light beam 214 is received by the light detector 206, which may be positioned outside the microfluidic channel 201. When particle 210 and fluid 208 are in the capture area 216, the light detector 206 can be used to determine the absorbance of the light beam 214 by particle 210 and fluid 208 to detect the size or otherwise characterize particle 210. Petition 870230102574, dated 11 / 22 / 2023, p. 39 / 110 32 / 78

[076] As used in this document, the term “path length” refers to the distance that light from the light source 202 travels in the fluid to be measured. In some embodiments, the path length may be approximately equal to the width or depth of the microfluidic channel 201. The path length may be small to improve sensitivity to particles 210. In some embodiments, the path length is less than or equal to 2000, 1000, 500, 300, 250, 200, 150, or 100 micrometers. In one or more embodiments, the path length is less than or equal to 1000 micrometers.

[077] The light source 202 is configured to generate light in a selected frequency band, such that the particle 210 has a different absorbance from the absorbance of the fluid 208 in the selected frequency band. In one or more embodiments, the particle 210 has a higher absorbance than the fluid 208, for example, when the liquid is water and the fluid 208 is a hydrocarbon fluid. In fuel system applications, for example, the light source 202 may generate the light 212 at least in the near-infrared (NIR) frequency band. In some embodiments, the NIR light 212 may include an emission peak or at least include frequencies in a range of 1400 to 1600 nanometers. In particular, the NIR light 212 may include an emission peak centered on or near 1550 nanometers. In some forms, NIR 212 light may include a peak emission or at least include frequencies in a range of at least 900 to 1100 nanometers.In particular, NIR 212 light may include a peak emission centered on or near 1000 nanometers.

[078] The light source 202 may include any suitable type of light source capable of providing light 212 in a selected frequency band. In some embodiments, the light source 202 is a light-emitting diode (LED). The LED light source 202 may be a low-power LED. In some embodiments, the LED light source emits omnidirectionally or in all directions from Petition 870230102574, dated 11 / 22 / 2023, pp. 40 / 110 33 / 78 of the light-emitting junction. In some embodiments, the LED light source emits primarily in one direction. In some embodiments, the light source 202 may be paired with or include a fiber optic cable that directs the light to the microfluidic channel 201. The light aperture 204 may be used to allow a narrow beam of light 214 through the microfluidic channel 201, which may facilitate the elimination of noise or false signals, for example, due to diffusion and reflectance.

[079] The light aperture 204 may or may not include a passage in the aperture element 218. As used herein, “aperture” refers to the passage, or empty space, within the aperture element 218. The light aperture 204 may have a width that is scaled relative to the microfluidic channel 201 and the light detector 206 to facilitate optimal sensitivity for detecting particles 210 in the fluid 208. In some embodiments, the width of the light aperture 204 is equal to or substantially equal to the channel width of the microfluidic channel 201.

[080] Additionally or alternatively, the light aperture 204 can be scaled relative to a predetermined particle size of interest. For example, in some embodiments, a light aperture width 204 can be designed to be less than or equal to 2, 3, 4, 5, 6, 7, 8, 9, or 10 times the particle size of interest. In some embodiments, a light aperture width 204 can be designed to be greater than or equal to 1, 2, 3, 4, 5, 6, 7, 8, or 9 times the particle size of interest.

[081] The light aperture 204 may have any suitable geometric shape. In some embodiments, the light aperture 204 has a round or circular shape, such as a circle or oval. In some embodiments, the light aperture 204 has a polygonal shape, such as a triangle, square, trapezoid, or rectangle. The light aperture 204 may have a length that may extend along the same direction as the fluid flow 208. In one or more embodiments, the length of Petition 870230102574, dated 11 / 22 / 2023, p. 41 / 110 34 / 78 light aperture 204 may be equal to or substantially equal to the width of the light aperture 204. Light detector

[082] The light detector 206 can be any suitable type of photodetector sensitive to the selected frequency band, which can be a NIR frequency band. The light detector 206 is also configured to provide a signal representing a quantity of light from the light beam 214 that remains after traversing the microfluidic channel 201. In particular, the light detector 206 can be configured to generate an electrical signal, such as a current, voltage, or power signal, in response to receiving light in the selected frequency band. Non-limiting examples of photodetector types include indium gallium arsenide (InGaAs), germanium (Ge), or silicon (Si) photodiodes. For example, an InGaAs photodiode can be sensitive to light 212 in a frequency band from 1100 to 1700 nanometers. A Ge photodiode can have a peak sensitivity at 1550 nanometers. A Si photodiode can be used for visible light. Controller

[083] The controller 110 can be configured to detect size or otherwise characterize one or more particles 210 dispersed in the fluid flow 208 based on the signal from the light detector 206. In some embodiments, the controller 110 can be configured to detect one particle 210 at a time dispersed in the fluid flow 208, particularly particles of a predetermined size.

[084] In general, when particle 210 is a fluid, the particle may also be called a droplet. When particle 210 is a liquid, the sign may be used to determine an amount of liquid (e.g., water) per unit volume of fluid 208 (e.g., hydrocarbon fluid), excluding the liquid dissolved in the fluid. Petition 870230102574, dated 11 / 22 / 2023, page 42 / 110 35 / 78

[085] In some embodiments, the controller 110 is configured to determine a particle rate through the capture area 216. For example, a change in absorbance detected based on the signal from the light detector 206 may indicate that particle 210 is entering or leaving the capture area 216. Alternatively or additionally, the controller 110 may be configured to determine a particle size. In some embodiments, the controller 110 may determine a particle rate or a particle size based on at least one of: a magnitude of a pulse contained in the signal, a width of a pulse contained in the signal, a first signal threshold level to detect a minimum particle size in the capture area, a second signal threshold level to detect a particle that fills the capture area, and a signal threshold level overrun rate.When the particle is a fluid, the controller 110 can determine a quantity of the particle 210 in the form of droplets per unit volume of fluid 208, as a particle concentration, based on the particle rate, particle size, or both. In some applications, such as non-motor applications, when a particle rate is regular or substantially regular, the particle rate can be used to estimate or determine a particle size or concentration.

[086] In some embodiments, the controller 110 is further configured to determine a quantity of droplet-shaped particles 210 per unit volume of fluid 208 based on the droplet rate and droplet size. The controller 110 can also be configured to determine a particle size based on the magnitude of a pulse contained in the signal data in response to the signal exceeding the second signal threshold level. The controller 110 can further be configured to determine a particle size based on the width of a pulse contained in the signal data in response to the signal exceeding the second signal threshold level. Additionally, the Petition 870230102574, dated 11 / 22 / 2023, page 43 / 110 The 36 / 78 110 controller can be configured to determine a particle size based on the particle rate. Capacitance-based sensor

[087] In other embodiments, a capacitance-based sensor (not shown) may be used as the particle sensor 112. In order to detect single particles and assess fuel purity, a capacitance sensor may be fabricated in the microfluidic channel 201, for example, near the outlet. Capacitance sensors may be used to detect particles 210, such as water or other liquid droplets or metallic particles. The capacitance sensor may include interdigitated electrodes to form a planar capacitor. The capacitance of this channel may be calculated from: Cpar = In (1 + 9 + J(1+9-1(Equation 4) where Sf is the dielectric of the fluid in the microfluidic channel and el, wea are the geometric dimensions of the electrodes. When a particle passes through the microfluidic channel, the change in capacitance can be simplified to (approximately proportional to): AC ô (ερ- ε^Αρ(Equation 5) where Sp is the dielectric of the particle and Ap is the area of ​​the particle.

[088] Capacitance sensors can be used to detect a variety of particles in a fluid, for example, when the dielectric difference between the particle material and the fluid is sufficient to produce a significant signal. Table 1 below shows the dielectric constant for various particles and fluids. Particle materials that have a greater difference in the dielectric constant from the base fluid may produce a greater signal difference. In general, the signal may also be related to particle size in addition to the dielectric difference between the particle and the base fluid. In the case where the size is known (or approximately known), which can be determined using the separation element of Petition 870230102574, dated 11 / 22 / 2023, page 44 / 110 37 / 78 particles 302 (see Figures 9-10), the signal can be used to determine the dielectric constant difference and possibly the contaminant material. Contaminant / Fluid Dielectric constant Oil ~3 Water 80 Fuel ~2.1 Polyethylene 2.25 Metals Very high Table 1

[089] Figure 7 is a conceptual diagram showing an example of an arrangement 220 for use of the particle sensor 112 in relation to a microfluidic channel 221. The microfluidic channel 221 may include an inlet 222 and an outlet 224 that has at least a first flow branch 226 and a second flow branch 228.

[090] The fluid flow 208 and the particles 210 in the fluid flow can be received at the inlet 222. Any particles 210 can be detected by the particle sensor 112 positioned along the microfluidic channel 221 to provide signal data representing a signal corresponding to the fluid 208 and the particles 210 dispersed in the fluid. The controller 110 can be operationally coupled to the particle sensor 112 to receive an indication that particles 210 have been detected.

[091] The controller 110 can be operationally coupled to a flow routing element 230 positioned along at least one flow branch 226, 228 of the outlet 224. In the illustrated embodiment, the flow routing element 230 includes a single valve 232 positioned between the first flow branch 226 and the second flow branch 228 to selectively divert fluid flow to one branch or the other. The Petition 870230102574, dated 11 / 22 / 2023, page 45 / 110 Controller 110 can be configured to control the flow routing element to direct fluid flow to the first flow branch 226, for example, until a particle threshold level 210 is detected by the particle sensor 112 in the microfluidic channel 221. Controller 110 can also be configured to determine if a particle threshold level 210 is present in the microfluidic channel 221 based on signal data from the particle sensor 112. In response to the determination that the particle threshold level 210 is present in the microfluidic channel 221, controller 110 can control the flow routing element 230 to direct fluid flow to the second flow branch 228.

[092] The 210 particle limit level may be determined in any suitable manner. Non-limiting examples include detection of one or more particles above a limit size, detection of a number of particles exceeding a limit number, detection of a limit rate (or frequency) of particles, or detection of a limit concentration of particles in the fluid.

[093] The controller 110 can also determine a flow rate of the fluid 208 in the microfluidic channel 221. The flow rate can be used to determine an appropriate timing for when to control the fluid routing element 230 to direct the fluid to the second flow branch 228 and a period for controlling the fluid routing element to direct the fluid back to the first flow branch 226.

[094] The flow routing element 230 may include one, two or more valves 232, solenoids, any other mechanisms suitable for diverting the flow of fluid 208. In some embodiments (not shown), the flow routing element 230 includes two valves 232, each positioned along one of the flow branches 226, 228. The valves 232 may be opened and Petition 870230102574, dated 11 / 22 / 2023, page 46 / 110 39 / 78 closed alternately to allow fluid 208 to flow through the first flow branch 226 or the second flow branch 228. Removing water droplets

[095] In some embodiments, arrangement 220 may be described as a water droplet removal system or water droplet diverting microfluidic system, which may be used for the removal of water droplets, such as particles 210, from a hydrocarbon fluid. The diverting system may include a microfluidic droplet diverter, or flow routing element 230, and a particle sensor 112 (e.g., optical or capacitance types) that may detect individual water droplets in the microfluidic channel 221. In the case where the microfluidic channel 221 contains a water droplet, the fluid may be diverted to a waste stream, such as the second flow branch 228, by means of a valve switch or other mechanism, such as the valve 232. The waste stream may be sent to a waste collection area, sent to a water removal filter (such as a barrier or coalescing filter), or returned to the main fuel tank.The time during which the fluid is diverted can be determined from the geometry of the microfluidic channel (such as dimensions and length between the sensor and the diverter valve) and the flow rate. After the water droplet is sent to the waste stream, the diverter valve can be switched so that the fluid is sent to the main outlet as the first flow branch 226. The main outlet is considered clean (as fuel without water droplets) and can be sent to a particulate removal filter, high-pressure common conduit system, or another part of the fuel system.

[096] In another configuration, the microfluidic water droplet diverter may include two valves. One valve may be in the main outlet channel, as the first flow branch 226, and the other may be in the waste outlet channel, or the second flow branch 228. The valves may be close to the junction Petition 870230102574, dated 11 / 22 / 2023, page 47 / 110 40 / 78 where the inlet flow channel, the waste outlet channel, and the main outlet channel meet and are thus incorporated into a microfluidic device. Alternatively, the valves may be detached from the junction and be independent of the microfluidic device (e.g., in the piping or plumbing leaving the device). When a drop of water is captured by the water droplet sensor, the main outlet valve may be closed and the waste outlet valve may be opened.

[097] The diverter system may contain more than one microfluidic channel to increase overall productivity. Multiple channels may or may not share the same particle sensor 112. The channel containing the water droplet can be detected by making the sensor output specific to that channel (see Figures 11A-B).

[098] The diverter system could also be used with a fuel system with two coalescing elements in parallel. When the water sensor positioned downstream of the first coalescing elements detects water, one or more valves can switch the flow from the first coalescing element to the second coalescing element. This can allow the actuators to switch the filters at a longer interval or at a more convenient time.

[099] Figure 8 is a conceptual diagram showing another example of an arrangement 240 for use of the particle sensor 112 in relation to a microfluidic channel 241 of a hydrodynamic separator 260, which can be described as a microfluidic separation channel. The microfluidic channel 241 may include an inlet 242 and an outlet 244 that has at least one first flow branch 246 and a second flow branch 248. As illustrated, the microfluidic channel 241 of the hydrodynamic separator 260 is curved. The curve may follow a circular shape. In other embodiments, the microfluidic channel 241 may be curved and have a multi-S shape. Any suitable curved shape may be used. Petition 870230102574, dated 11 / 22 / 2023, page 48 / 110 41 / 78 to provide sufficient inertial forces to orient the particles in a specific size range at a specific flow rate. Inlet 242 can be positioned at one end, or end region, and outlet 244 can be positioned at an opposite end, or end region.

[0100] The hydrodynamic separator 260 can be designed so that, at a predetermined fluid flow rate 208, the microfluidic channel 241 is configured to direct any particles 210 exceeding a corresponding limit size to the second flow branch 248 and any remaining particles to either the first flow branch 246 or the second flow branch 248 of the outlet 224.

[0101] The fluid flow 208 and the particles 210 in the fluid flow can be received at the inlet 242. Any particles 210 can be detected by the particle sensor 112 positioned along the microfluidic channel 241 to provide signal data representing a signal corresponding to the fluid 208 and the particles 210 dispersed in the fluid. The controller 110 (Figure 1) can be operationally coupled to the particle sensor 112 to receive an indication that particles 210 have been detected.

[0102] The controller 110 can be operationally coupled to the fluid pump 114 (Figure 1) in fluid communication with the microfluidic channel 241 of the hydrodynamic separator 260. The fluid pump 114 can be configured to direct the fluid through the microfluidic channels 241 of one or more hydrodynamic separators 260. The controller 110 can be configured to control the fluid pump to direct the fluid through the hydrodynamic separation element from the inlet 242 to the outlet 244. The controller 110 can also be configured to determine if a limit level of particles 210 is present in the microfluidic channel 241 based on signal data from the particle sensor 112. In response to the determination that the limit level of particles 210 is present Petition 870230102574, dated 11 / 22 / 2023, page 49 / 110 42 / 78 in the microfluidic channel 241, the controller 110 can control the fluid pump 114 to direct the fluid at the predetermined flow rate of the fluid 208 through the microfluidic channel of the hydrodynamic separator 260 to direct any particles exceeding the corresponding size limit to the second flow branch 248.

[0103] The particle sensor 112a, b can be positioned at any suitable location along the microfluidic channel 241. In some embodiments, the particle sensor 112a, b can be positioned between the inlet 242 and the outlet 244. In some embodiments, the particle sensor 112a can be positioned closer to the inlet 242. Closer to the inlet 242, particles 210 above the limit size may not be oriented along an inner wall 262 of the hydrodynamic separator 260. The particle sensor 112a can define a capture area (schematically illustrated as a solid line) that covers most or all of the width of the microfluidic channel 241 from the inner wall 262 to an outer wall 264. Closer to the outlet 244, particles 210 above the limit size may be oriented along the inner wall 262 of the hydrodynamic separator 260.A particle sensor 112b positioned towards the outlet 244 can define a capture area (schematically illustrated as a solid line) that covers part or less than half of the width of the microfluidic channel 241 from the inner wall 262 to the outer wall 264.

[0104] In general, when a droplet is captured, arrangement 240 can change the fluid flow to direct the droplet to the reject stream. The flow can be calibrated to remove droplets or particles of a specific size based on sizing information from particle sensor 112a, b. The flow could be changed with a pressure pulse, or changes in flow paths (such as opening or changing a valve position of one or more valves located at outlet 244). Petition 870230102574, dated 11 / 22 / 2023, pp. 50 / 110 43 / 78

[0105] In some embodiments, the waste stream, such as the second flow branch 248, may be only a fraction of the size of the total flow stream. This may minimize the impact on the total flow stream during droplet removal.

[0106] Figures 9-10 are conceptual diagrams showing another arrangement 300 for use of the particle sensor 112 with a particle separation element 302 and the microfluidic capture element 116. The arrangement 300 can be used to classify the particles 210 and to calculate a number of particles in different size ranges. Although a two-stage separation element 302 is shown to separate particles into three size ranges, any suitable number of stages (n) can be used to separate particles into different size ranges (n+1 size ranges).

[0107] In the illustrated embodiment, the particle separation element 302 is configured to classify the particles 210 into a first size range, a second size range, and a third size range in a first output stream 304 (containing particles in the first size range, the second size range, and the third size range), a second output stream 306 (containing particles in the second size range and the third size range), and a third output stream 308 (containing particles in the third size range) for capture by the microfluidic capture element 116. The particle sensor 112 can be positioned along the microfluidic capture element 116 to detect the number of particles in each output stream 304, 306, 308.Controller 110 (Figure 1) can determine a number of particles associated with each size range based on volume fractions associated with the flow branches of particle separation element 302.

[0108] As can be seen in Figure 10, the particle separation element 302 may include at least one first hydrodynamic separator 320 and Petition 870230102574, dated 11 / 22 / 2023, page 51 / 110 44 / 78 a second hydrodynamic separator 322. Each hydrodynamic separator 320, 322 can define a curved microfluidic channel to encounter particles of different size changes, which can be described as a microfluidic separation channel. The outlet of the first hydrodynamic separator 320 can include a first flow branch 326 and a second flow branch 328. The outlet of the second hydrodynamic separator 322 can include a first flow branch 330 and a second flow branch 332.

[0109] The second flow branch 328 of the first hydrodynamic separator 320 can be configured to provide the first outlet flow 304. The second flow branch 332 of the second hydrodynamic separator 322 can be configured to provide the second outlet flow 306. The first flow branch 330 of the second hydrodynamic separator 322 can be configured to provide the third outlet flow 308. The first flow branch 326 of the first hydrodynamic separator 320 can be in fluid communication or fluidly coupled to the inlet of the second hydrodynamic separator 322 to provide a fourth fluid flow 310.

[0110] The first hydrodynamic separator 320 can be configured to direct all particles in the first size range to the second flow branch 328. The first size range may include any particles exceeding a first size limit. Any remaining particles not exceeding the first size limit may be supplied to either the first flow branch 326 or the second flow branch 328. The remaining particles may be considered uniformly distributed. The ratio of remaining particles supplied to each branch 326, 328 may be determined based on the volume fractions associated with each branch 326, 328. In general, the first flow branch 326 may receive a first portion, and the second flow branch 328 may receive a second portion of any remaining particles that Petition 870230102574, dated 11 / 22 / 2023, page 52 / 110 45 / 78 do not exceed the first size limit. As can be seen in FIGURE 9, the first outflow stream 304 from the second branch 328 includes particles in each size range. None of the other outflow streams 306, 308 contain particles that exceed the first size limit.

[0111] The second hydrodynamic separator 322 can receive the flow from the first branch 326, including the second portion of any remaining particles that do not exceed the first size limit. The second hydrodynamic separator 322 can be configured to direct all particles in the second size range to the second flow branch 332. The second size range can include any particles that exceed a second size limit. Any remaining particles that do not exceed the second size limit can be supplied to either the first flow branch 330 or the second flow branch 332, which can only be particles in the third size range. The remaining particles can be considered uniformly distributed. The ratio of remaining particles supplied to each branch 330, 332 can be determined based on the volume fractions associated with each branch 330, 332.In general, the first branch of flow 330 can receive a first portion, and the second branch of flow 332 can receive a second portion of any remaining particles that do not exceed the second size limit. As can be seen in FIGURE 9, the second outflow 306 includes particles in both particle size ranges that do not exceed the first size limit, and the third outflow 308 includes only particles that do not exceed the second size limit.

[0112] The microfluidic capture element 116 may be in fluid communication with the particle separation element 302. The microfluidic capture element 116 may include a plurality of microfluidic channels 340, which may be described as microfluidic capture channels, each in Petition 870230102574, dated 11 / 22 / 2023, page 53 / 110 46 / 78 fluid communication with a different flow branching of the particle separation element 302. The microfluidic channels 340 can be arranged in parallel. In particular, each microfluidic channel 340 receives a different output flow 304, 306, 308. The particle sensor 112 can be positioned and configured to detect a number of particles flowing through each of the microfluidic channels 340.

[0113] Controller 110 can determine a number of particles in each size range by counting the number of particles of any size range in each outlet stream 304, 306, 308 in the microfluidic channels 340. For illustrative purposes, assuming that the volume fraction between each pair of flow branches is 1:1 and the number of remaining particles (the number of particles that do not exceed the particle size limit) is divided equally between the two branches, the number of particles in each outlet stream can be calculated as follows: ( n±(d > dj = c±- (c2+ c3) sH2(di > d > d2) = 2(c2- c3) [ n3(d < d2) = 4c3(Equations 6A, 6B, 6C) where n1 is the first size range, n2 is the second size range, n3 is the third size range, d1 is the first size limit, d2 is the second size limit, c1 is the number of particles counted in the first outflow stream 304, c2 is the number of particles counted in the second outflow stream 306 and c3 is the number of particles counted in the third outflow stream 308.

[0114] In general, the input of the particle separation element 302 can receive a random distribution of particles 210. The particle separation element 302 can classify the particles 210 into different output streams 304, 306, 308. The output streams 304, 306, 308 can be received by a microfluidic capture element 116. The particle sensor 112 can count the number of particles in each microfluidic channel 340 of the microfluidic capture element 116 and determine the number of particles in each size range. Petition 870230102574, dated 11 / 22 / 2023, page 54 / 110 47 / 78

[0115] In some embodiments, the particle sensor 112 may include a detector aligned to each microfluidic channel 340 to count the number of particles in each channel. In other embodiments, the particle sensor 112 may use a detector shared across multiple channels to count the number of particles in each channel.

[0116] Arrangement 300 can be described as a microfluidic particle sensor, which can be used to measure the purity level of fluid in liquid applications. In one example, the microfluidic particle sensor can be used in diesel fuel filtration systems to measure fluid purity. The sensor can be placed upstream of a filter, downstream of a filter, or as a bypass to a filter. The sensor may include a segmentation stage, or particle separation element 302, which divides the particles into stream courses, for example, based on ISO purity codes, which may include particles of 4 to 6 micrometers in a first stream, particles of 6 to 14 micrometers in a second stream, and particles larger than 14 micrometers in a third stream.Particle sizes smaller than 4 micrometers may not be accounted for, or an additional stage may be added (four equal stages) to capture particles smaller than 4 micrometers, from 4 to 6 micrometers, from 6 to 14 micrometers, and larger than 14 micrometers. The microfluidic particle sensor can also be used in hydraulic or lubricant applications.

[0117] The sensor can be described as having two stages. The first stage can be described as a “segregating stage,” such as the particle separation element 302, which directs particles to specific current paths based on particle size. The second stage can be described as a “capturing stage,” including multiple capture channels, such as the microfluidic capture element 116, where current paths containing specific particulates are sent to different channels. Each individual channel Petition 870230102574, dated 11 / 22 / 2023, page 55 / 110 48 / 78 has a particle sensor or particle counter. The design of the segregation stage can dictate which particle size range operates in each channel. By counting or otherwise detecting particles in a capture channel, a particle size distribution can be determined.

[0118] Once the particles have been directed to current paths based on their particle size, the current paths can be sent to different pickup channels, such as microfluidic channels 340. Each pickup channel corresponds to a particle size range (based on the design and performance of the segregating stage). Each pickup channel can be associated with a particle sensor. The particle sensor can detect, or count, the passage of a particle in the pickup channel. The particle sensor can be optical (using absorbance, fluorescence, or light scattering, or other optical methods), electronic (using a capacitance sensor or impedance sensor), or magnetic. Pickup channels can share a single particle sensor when the signal emitted from each channel is unique.

[0119] This microfluidic particle sensor, which uses a passive particle orientation scheme upstream of particle counters, may not require calibration as particles are counted. This can allow for ease of fabrication. The microfluidic particle sensor can also be designed to work with a range of different particle types that have different properties, such as electronic or magnetic properties. The microfluidic particle sensor can also count individual particles one by one, instead of a bulk fluid reading, which can lead to increased sensitivity. The use of microfluidic channels can also minimize the effect of the base or carrier fluid.

[0120] Figures 11A-B are conceptual diagrams that show an example of the technique for counting the number of particles in multiple channels. Petition 870230102574, dated 11 / 22 / 2023, pp. 56 / 110 49 / 78 microfluidics 340a, 340b, 340c using a shared light detector, such as light detector 206 (Figure 6). An aperture element 350 may be similar to aperture element 218 (Figure 6), except that aperture element 350 includes a plurality of apertures 204 aligned to each microfluidic channel 340a, 340b, 340c. Each set of apertures 204 may define a unique spacing pattern along the corresponding microfluidic capture channel 340a, 340b, 340c. Unique spacing patterns may also be described as a unique hole pattern.

[0121] The controller 110 (see Figure 6) can be configured to determine signal data based on the signal from the light detector 206 and to determine whether a particle has traversed the capture area 216 based on the signal data. The controller 110 can determine the unique spacing pattern associated with the particle that traversed the capture area 216 based on the signal data. In particular, a particle traversing the microfluidic capture channel 340a can provide first unique signal data 342a, a particle traversing the microfluidic capture channel 340b can provide second unique signal data 342b, and a particle traversing the microfluidic capture channel 340c can provide third unique signal data 342c.The signal processing or pattern recognition processing by controller 110 can be configured to distinguish these unique patterns to identify the corresponding microfluidic capture channel 340a, 340b, 340c and the number of particles in the corresponding microfluidic capture channel.

[0122] In general, unique spacing patterns provide different timing profiles for a droplet moving through a specific microfluidic capture channel 340a, 340b, 340c. In the illustrated embodiments, a series of holes is placed at different distances from each other, so that a droplet moving through the channel provides several signal drops and the timing pattern of Petition 870230102574, dated 11 / 22 / 2023, page 57 / 110 50 / 78 drops are specific to the channel. A unique signal can also be created with a hole pattern that provides a different signal profile (such as differently shaped hole patterns). Unique spacing and unique shapes can also be used together. In the case where multiple drops are present in the channels, signal deconvolution algorithms can be used to distinguish individual channels.

[0123] In some embodiments, a diffraction grating may also be used to control the light entering the channels. The diffraction grating may be in the channel or inserted into the channel and directs the optical path towards a specific detector in a detector array.

[0124] Although the present disclosure is not limited to this, an understanding of various aspects of the disclosure will be gained through a discussion of the specific examples and illustrative embodiments provided below, which provide particle separation for supplementary or substitute filters. Various modifications of the examples and illustrative embodiments, as well as additional embodiments of the disclosure, will become apparent in the present document.

[0125] Figure 12 is a conceptual diagram showing an example of a 360 fluid system that can be used to remove particles using the particle separation element 102. The particle separation element 102, which may include a hydrodynamic separator element, can be used in a 360 fluid system along a main flow line 362.

[0126] As illustrated, the fluid pump 114 can be used to provide a fluid flow from the fluid source 104 through the particle separation element 102 to the main flow line 362. The particle separation element 102 can provide a main output flow using the first flow branch 363 and a secondary output flow using the second flow branch 364. The first flow branch 363 and the second Petition 870230102574, dated 11 / 22 / 2023, pp. 58 / 110 51 / 78 branch flow 364 can be recombined along the main flow line 362 upstream of the fluid destination 106, which may include the remainder of the system 360.

[0127] The secondary outflow can be provided to a filter 366 along the second flow branch 364 upstream of the recombination with the main outflow. Optional filters 368 can be positioned, for example, along the first flow branch 363 upstream of the recombination or along the main flow line 362 downstream of the recombination.

[0128] The particle separation element 102 can be positioned upstream or downstream of the fluid pump 114. In the illustrated embodiment, the particle separation element 102 is positioned downstream of the fluid pump 114.

[0129] The particle separation element 102 can be configured to remove particles larger than a specific diameter limit size from the main flow line 362, while the fluid pump 114 supplies fluid at a specific flow rate.

[0130] The separator element 102 can be used to direct particles above a specific size limit to a portion of the total fluid flow. The concentrated particle stream can be directed, or oriented, to the secondary outlet flow along the second branch 364, which can be supplied to the filter 366, which can be described as a final filter, to remove particles. After passing through the filter 366, the fluid from the concentrated particle stream of the second flow branch 364 can be combined with the remaining fluid from the first flow branch 363 and distributed to the rest of the system shown as the fluid destination 106. Particles above the critical size can be largely removed from the total fluid supplied to the fluid destination 106.

[0131] In the 360 ​​system, only a portion of the total fluid flow is filtered through the 366 filter. In some embodiments, the concentrated particle stream Petition 870230102574, dated 11 / 22 / 2023, pp. 59 / 110 The 52 / 78 supplied to the second flow branch 364 may include less than 50% of the total fluid volume, less than 25% of the total fluid volume, or less than 10% of the total fluid volume. The flow rate through filter 366 may be lower than, for example, in systems where particle separation element 102 was not used. The lower flow rate may lead to a lower pressure drop across the filter, a longer filter life, or both.

[0132] Additional filters 368 can be used to remove particles below the critical size, for example, along the “clean stream” course along the first flow branch 363, or along the main flow line 362, after the fluid stream courses are combined. A flow measurement, or variable pressure object, in the clean stream along the first flow branch 363 can be used to properly balance the flow between the two streams exiting the separator element 102.

[0133] The technique of coupling the separator element 102 to a filter can be used in various applications, such as engine fuel, engine oil, engine hydraulics and stationary hydraulics. This technique can be particularly useful in engine oil, engine hydraulics or stationary hydraulics, where the fluid is recirculated through the filtration system. EXAMPLES Device manufacturing

[0134] In Example 1, hydrodynamic separators were fabricated as microfluidic devices from polydimethylsiloxane (PDMS) using standard soft photolithography techniques. Briefly, a photomask was prepared using DraftSight and printed at 20000 dpi (CAD / Art Services, Inc.; Brandon, Oregon). The SU-8 mold was prepared using SU-8 2100 photoresistant material (MicroChem, Inc.; Newton, MA). Process parameters are described in the SU-8 2100 datasheet provided by MicroChem. PDMS (Sylguard 184; Dow Corning; Petition 870230102574, dated 11 / 22 / 2023, pages 60 / 110 53 / 78 A 10:1 w / w ratio (base:curing agent) was poured onto the mold, degassed for 30 minutes, and cured overnight in an oven at 85°C. After removing the PDMS from the pellet, inlet and outlet holes were drilled with biopsy needles. Scotch tape was used to remove particles and fibers from the PDMS. The final device was prepared by plasma bonding the PDMS to a glass slide using a Harrick Plasma cleaner at 800 microns (mtorr) for 1 minute. The finished device was placed on a hot plate at approximately 100°C for 15 minutes. The devices were designed with a constant radius of curvature, channel width, and channel depth. Particle imaging

[0135] In Example 2, fluorescent particles were suspended in deionized water for testing (Table 1). Particles of 2, 10, and 20 micrometers (µm) were provided in an aqueous suspension. These samples were diluted and tested directly.

[0136] The 25 μm and 30 μm particles were supplied as a powder. These samples were added with sodium dodecyl sulfate (SDS) surfactant to deionized water to prepare the test solution.

[0137] A typical mixture contained 50 mg of particles, 100 mg of SDS and 500 ml of deionized water. Particle size distributions were confirmed with a laser diffraction particle sizer (BeckmanCoulter LS-320).

[0138] The hydrodynamic separators, produced according to Example 1, were fed with particles using a pressure-driven flow system (ElveFlow OB1-Mk3; Elvesys; Paris, France). The system contained an in-line flow meter to measure the flow in real time (Elveflow FS4 (0 - 1 ml / min) or FS5 (0.2 - 5 ml / min); Elvesys; Paris, France). The flow was controllable by pressure or by flow rate within the ESI software package. Petition 870230102574, dated 11 / 22 / 2023, pp. 61 / 110 54 / 78

[0139] The orientation of particles in hydrodynamic separators was measured optically using an Olympus IX-73 inverted microscope (Olympus Life Science; Waltham, MA) coupled to a short-arc mercury vapor lamp (U-HGLGPS, Olympus Life Science; Waltham, MA). A fluorescence filter cube was selected to match the absorbance and emission characteristics of the fluorescent particles. Images were obtained with a 10x objective. Images were captured using a BSI sCMOS camera (Teledyne Photometries; Tuscan, AZ) using MicroManager (version 1.4; https: / / micro- (manager.org / wiki / Micro-Manager). Particle size (pm) Source Part number Optical properties of the particle Àex (nm) Àem (nm) 2 SigmaAldrich L3030 553 635 10 Polysciences, Inc. 18140-2 441 485 20 Polysciences, Inc. 19096-2 441 485 25 Cospheric LLC UVPMS-BR-0.995 22-27 pm 300 - 550 605 30 Cospheric LLC UVPMS-BR-1.090 27-32 pm 300 - 550 605 Table 2: Properties of fluorescent particles

[0140] Before injecting the particles, a pressure-flow calibration was determined for each hydrodynamic separator using deionized water (Dl), to calibrate unreliable flow meter readings for solutions containing particles. The data were fitted to a second-degree polynomial and used to determine operating pressures for desired experimental flow rates. Petition 870230102574, dated 11 / 22 / 2023, pp. 62 / 110 55 / 78

[0141] During the particle experiments, the system pressure was controlled, and pressure-flow data were recorded. If the pressure-flow data showed decay over the experimental time period, it was assumed that the particles were collected in one place in the device, and the data was not recorded.

[0142] After the experiment, the device was cut in half and the channel depth was measured optically on the Keyence VHX digital microscope (Keyence; Itasca, IL).

[0143] Once the pressure-flow relationship of a device was calibrated, an experiment was run at a constant Dean number, or flow rate, with a single fluorescent particle solution. Fluorescence images were obtained at various angles through the device to measure particle orientation as a function of length (L = αRc, where α is the angle through the device in radians and R is the radius of curvature measured on the inner wall). The angles were set around the circular shape of each hydrodynamic separator, for example, as shown in Figure 14. Figure 14 is a conceptual diagram showing relative angle positions around a 400° hydrodynamic separator at the inlet 10° (A), 180° (B), 270° (C) and at the outlet 350° (D). The integration time of the cMOS camera was adjusted to maximize signal differences without saturating any pixels.

[0144] The extent of particle orientation was determined using image analysis in the open-source software ImageJ. Pixel intensity was measured across the channel at each imaged location of the device. Pixel intensity is assumed to be proportional to the average particle concentration. The particle orientation location was determined from the output image (340° or 350°). For each image, the orientation percentage was determined as the ratio between the Petition 870230102574, dated 11 / 22 / 2023, pp. 63 / 110 56 / 78 integrated pixel intensity in the oriented region and the integrated pixel intensity of the entire channel as follows: F% = iorientedI(x^ (Equation 7) icanalI(x)

[0145] Figure 13A shows a representative image of the device input at 380 degrees. Figure 13B shows a representative image of the device output at 350 degrees. Figure 13C is a plot of pixel intensity versus channel position (in pixels) through the channel indicated by line 384 in Figure 13A. Figure 13D is a plot of pixel intensity versus channel position (in pixels) through the channel indicated by line 386 in Figure 13B. Boxes 394 and 396 were considered the oriented regions. Orientation studies: Same device, different Dean numbers (140 µm depth: 25 µm particles)

[0146] In Example 3, 25 pm particles were oriented in a hydrodynamic separator (channel width: 500 pm, channel depth: 140 pm, radius of curvature: 20 mm) at two Dean numbers. A plot 410 showing the oriented percentage versus channel length data is shown in Figure 15 for Dean number 15 at 1010 mbar pressure (3.97 ml / min). Plot 410 shows three distinct regions: an initial region 412, where the particles are not being oriented, a region 414, where the particles are oriented, and a region 416, where the particles have become fully oriented.

[0147] At the device inlet, the particles are approximately 35% oriented. The amount of orientation does not increase for the first 14 mm of channel length, which may occur due to particle migration from the center of the channel to the edges of the channel due to shear-lift forces. This region 412 of the device can be described as the particle migration region and has a length L0. This length may depend on particle size, fluid properties, and flow rate. Petition 870230102574, dated 11 / 22 / 2023, pp. 64 / 110 57 / 78

[0148] After the particle migration region, the percentage of particles that have been oriented can increase linearly with respect to channel length. This region 414 of the device can be described as the linear orientation region. The linear adjustment coefficient can be described as the linear orientation rate (rf). The percentage of oriented particles generally increases linearly up to a maximum value.

[0149] Once the maximum particle orientation value is reached, the particle orientation can become approximately constant. This region 416 of the device can be described as the fully oriented region. In this example, the maximum orientation percentage (fm) shown in the fully oriented region is about 90% (i.e., 90% of the particles are oriented).

[0150] The length of the hydrodynamic separator that can be used to achieve a target orientation percentage can be described as follows: Ld = Lo + 2dÁ (Equation 8)rf where Ld is the channel length of the hydrodynamic separator required to achieve the target orientation percentage, L0 is the length of the particle migration region, rf is the linear orientation rate, fc is the particle orientation percentage at the inlet (and during the particle migration region 414), and ft is the target orientation percentage. This equation can be used particularly when f0 < ft < fm.

[0151] Table 3 shows data for orientation experiments with the same device performed at different Dean numbers. The length of the particle migration region and the length required to achieve 90% orientation are similar and nearly identical. Petition 870230102574, dated 11 / 22 / 2023, pp. 65 / 110 58 / 78 Dean Number Particle migration region length - Lo (mm) Linear orientation rate - rf (% oriented / mm) Length required to achieve 90% orientation Ld (mm) 10 14 0.57% 110 15 14 0.58% 108 Table 3: Guidance data for experiments with the same device, but a different Dean number. Experiments with the same Dean number, but a different device (104 µm depth: 30 µm particles)

[0152] In Example 4, an experiment similar to Example 3 was performed with approximately the same Dean numbers, but in devices with two different radii of curvature. 30 pm particles were used. The results of the experiment are shown in Table 4. The length of the particle migration region was shorter for the device with the smaller radius of curvature. In addition, the linear orientation rate was higher for the device with the smaller radius of curvature. Based on these results, the length required to orient up to 50% of particles, for example, was shorter for the device with the smaller radius of curvature. Radius of curvature - Rc (mm) Dean number Length of particle migration region Lo (mm) Linear orientation rate - π (% oriented / mm) Length required to achieve 50% orientation Ld (mm) Approximate pressure drop required to achieve 50% orientation - Pd (mbar) 10 21 5 0.91% 35 600 20 23 10 0.58% 75 1500 Petition 870230102574, dated 11 / 22 / 2023, pp. 66 / 110 59 / 78 Table 4: Guidance data for experiments with the same Dean number, but a different device.

[0153] In general, the device with the smallest radius of curvature can achieve a target Dean number with a lower flow rate than a device with a larger radius of curvature. Comparing the pressure drop required to guide particles, a smaller radius of curvature can result in a shorter channel and a lower flow rate, which can have a large impact on the pressure drop.

[0154] As an example, from the data in Table 4 and the experimental pressures applied, the pressure drop associated with a hydrodynamic separator designed to orient 50% of the particles was calculated from the following equation: nLd 360°;'d;-'~— (Equation 9) where Papp is the experimentally applied pressure, Ld is the length required to achieve 50% orientation (Table 4), Rc is the radius of curvature of The 360° device (Table 4) and the term 35()!!.2π. represent the experimental device design in which the device covered only 350° of the arc length of the circle to allow for inlet and outlet ports. The calculated pressure drops are shown in Table 4. The device with the smallest radius of curvature was used to orient the particles at a much lower pressure drop. Length of the linear orientation region

[0155] It has recently been found that the length of the linear orientation region required to achieve maximum particle orientation (85%-95% particle orientation) can be described by the following relationship: Lf K3L·^L = iRs Í2LΫ (Equation 10) J De2DhRe \DhJ 'M y 7em where Re is the Reynolds number, De is the Dean number, and DH is the hydraulic diameter of the hydrodynamic separator, w is the channel width, and Rc is the radius. Petition 870230102574, dated 11 / 22 / 2023, pp. 67 / 110 60 / 78 curvature of the hydrodynamic separator. More specifically, the ratio is as follows: Lf = 156.2 (D$ + 24.3 (Equation 11)

[0156] Furthermore, the length of the linear orientation region required to achieve maximum particle orientation for a specific particle size can be described by the following relation: Lf = 1598.8 + 6.4 (Equation 12) where a is the particle diameter. The particle diameter can be the equivalent spherical diameter for particles that have a sphericity greater than 0.5. This equation can be a predictor of the length of the linear orientation region for particles that have a diameter greater than 8% of the hydraulic channel diameter and less than or equal to 50% of the channel height.

[0157] The total length for a hydrodynamic separator can be determined or calculated as follows: Ld = Lo + Lf (Equation 13)

[0158] This equation can be used to calculate minimum hydrodynamic separator channel lengths required to achieve maximum particle orientation for various applications. Experimental results demonstrate that the particle migration region length L0 is in the range of 0% to 29% of the total hydrodynamic separator length Ld required to achieve maximum particle orientation. Additionally, the data show that the particle migration region length L0 is in the range of 0% to 40% of the linear orientation region length Lf. Therefore, the hydrodynamic separator channel length Ld can be greater than or equal to the linear orientation region length Lf to achieve maximum particle orientation. The hydrodynamic separator channel length Ld can be, at most, 40% greater than the linear orientation region length Lf to achieve a Petition 870230102574, dated 11 / 22 / 2023, pp. 68 / 110 61 / 78 particle orientation that is balanced with minimizing the pressure drop across the channel. ILLUSTRATIVE MODALITIES

[0159] Some embodiments refer to a hydrodynamic separator.

[0160] In modality A1, a system comprises: A hydrodynamic separation element comprising one or more hydrodynamic separators, each defining a curved microfluidic channel in fluid communication, wherein each microfluidic channel defines: an inlet configured to receive a fluid and the particles dispersed in the fluid, wherein the particles have a composition different from the fluid, and an outlet comprising a first flow branch and a second flow branch, in which, at a predetermined flow rate, each microfluidic channel is configured to direct any particles exceeding a corresponding size limit to the second flow branch and any remaining particles to either the first or second flow branch; A particle sensor positioned along one or more hydrodynamic separators, configured to provide signal data representing a signal corresponding to the fluid and the particles in the fluid; and a controller operationally coupled to the particle sensor to receive the signal data and operationally coupled to a fluid pump in fluid communication with the hydrodynamic separation element, wherein the controller is configured to: Control the pump to direct the fluid through the hydrodynamic separation element. Petition 870230102574, dated 11 / 22 / 2023, pp. 69 / 110 62 / 78 determine if a limit level of particles is present in at least one microfluidic channel based on signal data from the particle sensor, and control a flow rate through the hydrodynamic separation element in response to the determination that the limit level of particles is present in at least one microfluidic channel, to direct the fluid at the predetermined flow rate through the hydrodynamic separation element to guide any particles exceeding the corresponding limit size to the second flow branch of at least one microfluidic channel.

[0161] In modality A2, a system includes the system according to Modality A1, where the particle sensor comprises: a light source configured to direct a beam of light in a frequency band along a path through at least one hydrodynamic separator, wherein the frequency band is selected so as to have an absorbance by the particles different from the absorbance by the fluid; an aperture element that defines a light aperture positioned in the path of the light beam coming from the light source; and a light detector positioned to receive the light beam in a capture area after passing through at least one hydrodynamic separator and the light aperture, wherein the light detector is configured to provide signal data representing a quantity of light in the frequency band that remains after passing through at least one hydrodynamic separator.

[0162] In embodiment A3, a system includes the system according to Embodiment A1, wherein the particle sensor comprises a capacitance sensor.

[0163] In modality A4, a system includes the system according to any previous modality A, and also includes a reservoir of Petition 870230102574, dated 11 / 22 / 2023, pp. 70 / 110 63 / 78 originates from fluid communication with the inlet and the second flow branch, where fluid and particles are pumpable from the source reservoir to the hydrodynamic separation element and selectively back to the source reservoir through the second flow branch.

[0164] Some embodiments refer to a particle deflector.

[0165] In modality B1, a system comprises: a particle separation element comprising: One or more microfluidic channels in parallel fluid communication, where each microfluidic channel defines: an inlet configured to receive a fluid and the particles dispersed in the fluid, where the particles have a different composition from the fluid, and an outlet comprising a first flow branch and a second flow branch; a flow routing element positioned along at least one flow branch with at least one output; A particle sensor positioned along one or more microfluidic channels configured to provide signal data representing a signal corresponding to the fluid and the particles dispersed in the fluid; and a controller operationally coupled to at least one flow routing element and operationally coupled to the particle sensor to receive the signal data, wherein the controller is configured to: to control the flow routing element to direct fluid flow to the first flow branch of at least one outlet of at least one microfluidic channel, to determine if a threshold particle level is present in at least one microfluidic channel based on signal data from the particle sensor, and Petition 870230102574, dated 11 / 22 / 2023, pp. 71 / 110 64 / 78 control the flow routing element in response to the determination that the limit level of particles is present in at least one microfluidic channel, to direct the fluid flow to the second flow branch of at least one microfluidic channel.

[0166] In embodiment B2, a system comprises the system according to Embodiment B1, wherein the particle separation element comprises a hydrodynamic separator element that includes one or more hydrodynamic separators, wherein the one or more hydrodynamic separators comprise one or more microfluidic channels, wherein each microfluidic channel is curved.

[0167] In embodiment B3, a system comprises the system according to Embodiments B1 or B2, wherein the particle sensor comprises: a light source configured to direct a beam of light in a frequency band along a path through at least one microfluidic channel, wherein the frequency band is selected so as to have an absorbance by the particles different from the absorbance by the fluid; an aperture element that defines a light aperture positioned in the path of the light beam coming from the light source; and a light detector positioned to receive the light beam in a capture area after passing through at least one microfluidic channel and the light aperture, wherein the light detector is configured to provide signal data representing a quantity of light in the frequency band that remains after passing through at least one microfluidic channel.

[0168] In embodiment B4, a system comprises the system according to Embodiments B1 or B2, wherein the particle sensor comprises a capacitance sensor.

[0169] In modality B5, a system comprises the system according to any previous modality B, and also includes a reservoir of Petition 870230102574, dated 11 / 22 / 2023, pp. 72 / 110 65 / 78 originates from fluid communication with the inlet and the second flow branch, where fluid and particles are pumpable from the source reservoir to the hydrodynamic separation element and selectively back to the source reservoir through the second flow branch.

[0170] Some modalities refer to a particle classifier.

[0171] In C1 mode, a system comprises: A hydrodynamic separation element comprising a plurality of hydrodynamic separators in series fluid communication, including at least one first hydrodynamic separator and a second hydrodynamic separator, wherein each defines a curved microfluidic separation channel for separating particles of different size ranges, each microfluidic separation channel defining: an inlet configured to receive a fluid containing particles, and an outlet comprising a first flow branch and a second flow branch, wherein, at a specific flow rate, each microfluidic separation channel is configured to direct any particles exceeding a corresponding size limit to the second flow branch and any remaining particles to either the first or second flow branch, wherein the first flow branch of the first hydrodynamic separator is in fluid communication with the inlet of the second hydrodynamic separator; and Petition 870230102574, dated 11 / 22 / 2023, pp. 73 / 110 66 / 78 a microfluidic capture element in fluid communication with the hydrodynamic separation element, wherein the microfluidic capture element comprises a plurality of microfluidic capture channels, each in fluid communication with a different flow branch of the hydrodynamic separation element, wherein the plurality of microfluidic capture channels comprises at least: A first microfluidic collection channel in fluid communication with the second flow branch of the first hydrodynamic separator to receive any particles exceeding a first size limit, and a second microfluidic collection channel in fluid communication with the second flow branch of the second hydrodynamic separator to receive any particles exceeding a second size limit, wherein the first size limit is larger than the second size limit.

[0172] In embodiment C2, a system comprises the system according to Embodiment C1, wherein the plurality of microfluidic separation channels comprises a third hydrodynamic separator in fluid communication with the first flow branch of the second hydrodynamic separator.

[0173] In modality C3, a system comprises the system according to Modalities C1 or C2, and also includes: A particle sensor positioned along the plurality of microfluidic capture channels is configured to provide signal data representing a signal corresponding to the particles in the fluid; and a controller operationally coupled to the particle sensor receives the signal data, the controller being configured to determine a number of particles associated with each size range based on volume fractions associated with the flow branches based on the signal data. Petition 870230102574, dated 11 / 22 / 2023, pp. 74 / 110 67 / 78

[0174] In embodiment C4, a system comprises the system according to Embodiment C3, wherein at least one microfluidic separation channel comprises an outlet comprising a first outlet branch and a second outlet branch, further comprising at least one flow routing element positioned along the outlet of at least one microfluidic intake channel, wherein the controller is operationally coupled to at least one flow routing element and further configured to control the flow routing element to direct fluid flow to the second outlet branch in response to particle detection in the corresponding microfluidic intake channel.

[0175] In embodiment C5, a system comprises the system according to Embodiments C3 or C4, wherein the particle sensor comprises a capacitance sensor.

[0176] In the C6 embodiment, a system comprises the system according to the C3 or C4 Embodiments, wherein the particle sensor comprises: a light source configured to direct a beam of light in a frequency band along a path through at least one microfluidic capture channel, wherein the frequency band is selected so as to have an absorbance by the particles different from the absorbance by the fluid; an aperture element that defines a light aperture positioned in the path of the light beam coming from the light source; and a light detector positioned to receive the light beam in a capture area after passing through the light aperture and at least one microfluidic capture channel, wherein the light detector is configured to provide signal data representing a quantity of light in the frequency band that remains after passing through at least one microfluidic capture channel. Petition 870230102574, dated 11 / 22 / 2023, pp. 75 / 110 68 / 78

[0177] In embodiment C7, a system comprises the system according to Embodiment C6, wherein the aperture element comprises a plurality of light apertures which includes the light aperture positioned in the path of the light beam from the light source, wherein the plurality of light apertures comprises a set of different light apertures aligned to each microfluidic capture channel, wherein each set of light apertures defines a unique spacing pattern along the corresponding microfluidic capture channel, and wherein the light detector is positioned to receive the light beam in the capture area after traversing the plurality of light apertures and the plurality of microfluidic capture channels, and wherein the controller is configured to determine the number of particles associated with each size range based on the unique spacing pattern.

[0178] Some modalities refer to hole patterns.

[0179] In modality D1, a system comprises: a plurality of microfluidic collection channels, each configured to receive a flow of a fluid and particles dispersed in the fluid, where the particles have a different composition from the fluid; a light source configured to direct a beam of light in a frequency band along a path through a plurality of microfluidic pickup channels, wherein the frequency band is selected so as to have an absorbance by the particles different from the absorbance by the fluid; an aperture element that defines a plurality of light apertures comprising a set of different light apertures aligned with each microfluidic capture channel, wherein each set of light apertures defines a unique spacing pattern along the corresponding microfluidic capture channel; Petition 870230102574, dated 11 / 22 / 2023, pp. 76 / 110 69 / 78 a light detector positioned to receive the light beam in a capture area after passing through the plurality of light apertures of the aperture element and through the plurality of microfluidic capture channels, the light detector being configured to provide a signal representing a quantity of light in the frequency band that remains after passing through the plurality of microfluidic capture channels; and a controller operationally coupled to the light detector and configured to: To determine signal data based on the signal from the light detector, to determine if a particle crossed the capture area based on the signal data, and to determine the unique spacing pattern associated with the particle that crossed the capture area based on the signal data.

[0180] In the D2 mode, a system comprises the system according to the D1 mode, wherein each microfluidic collection channel is configured to receive particles in a different size range, and the controller is further configured to determine a number of particles associated with each size range.

[0181] In embodiment D3, a system comprises the system according to Embodiments D1 or D2, further comprising a hydrodynamic separation element positioned upstream of the plurality of microfluidic capture channels, wherein the hydrodynamic separation element comprises a plurality of hydrodynamic separators in series fluid communication which includes at least one first hydrodynamic separator and one second hydrodynamic separator, each defining a curved microfluidic separation channel to separate particles of different size ranges, each microfluidic separation channel defining: Petition 870230102574, dated 11 / 22 / 2023, pp. 77 / 110 70 / 78 an inlet configured to receive the fluid and the particles dispersed in the fluid, and an outlet comprising a first flow branch and a second flow branch, wherein, at a specific flow rate, each microfluidic separation channel is configured to direct any particles exceeding a corresponding size limit to the second flow branch and any remaining particles to either the first flow branch or the second flow branch, wherein the first flow branch of the first hydrodynamic separator is in fluid communication with the inlet of the second hydrodynamic separator.

[0182] In the D4 mode, a system comprises the system according to the D3 mode, wherein the controller is further configured to determine a number of particles associated with each size range based on volume fractions associated with flow branches based on signal data.

[0183] In the D5 embodiment, a system comprises the system according to the D3 or D4 Embodiments, wherein the controller is operationally coupled to a fluid pump in fluid communication with the hydrodynamic separation element, and the controller is configured to control the fluid pump to direct fluid at the specified flow rate through the hydrodynamic separation element.

[0184] In embodiment D6, a system comprises the system according to any of the Embodiments D3 to D5, wherein at least one microfluidic capture channel comprises an outlet comprising a first outlet branch and a second outlet branch, further comprising at least one flow routing element positioned along the outlet of at least one microfluidic capture channel, wherein the controller is coupled in such a way Petition 870230102574, dated 11 / 22 / 2023, pp. 78 / 110 71 / 78 operational to at least one flow routing element and additionally configured to control the flow routing element to direct fluid flow to the second outlet branch in response to particle detection in the corresponding microfluidic capture channel.

[0185] Some modalities refer to the detection of water droplets.

[0186] In embodiment E1, a system comprises the system according to any embodiment A, any embodiment B, any of the Embodiments C4 to C8 or any Embodiment D, in which the particles comprise a fluid other than the fluid.

[0187] In the E2 mode, a system comprises the system according to the E1 mode, wherein the controller is additionally configured to determine a quantity of the second fluid in the form of droplets per unit volume of fluid based on the signal data.

[0188] In the E3 modality, a system comprises the system according to the E2 modality, wherein the quantity excludes the second fluid dissolved in the fluid.

[0189] In E4 mode, a system comprises the system according to any previous E mode, wherein the controller is configured to determine a droplet rate or a droplet size of one or more droplets of the second fluid dispersed in the fluid stream based on signal data.

[0190] In Mode E5, a system comprises the system according to Mode E4, wherein the controller is configured to determine the droplet rate or droplet size based on at least one of: a magnitude of a pulse contained in the signal data, a width of a pulse contained in the signal data, a first signal threshold level to detect a minimum-sized droplet in the pickup area, Petition 870230102574, dated 11 / 22 / 2023, pp. 79 / 110 72 / 78 a second signal threshold level to detect a droplet that fills the capture area, and a signal threshold level overshoot rate.

[0191] In mode E6, a system comprises the system according to mode E5, wherein the controller is additionally configured to determine at least one of: a quantity of a second fluid in the form of droplets per unit volume of fluid based on the droplet rate and droplet size; The droplet size is based on the magnitude of a pulse contained in the signal data in response to the signal not exceeding the second signal threshold level; The droplet size is based on the width of a pulse contained in the signal data in response to the signal exceeding the second signal threshold level; and the droplet size is based on the droplet rate.

[0192] In embodiment E7, a system comprises the system according to any previous Embodiment E, wherein the fluid comprises a hydrocarbon fluid, and the second fluid comprises water.

[0193] Some modalities refer to a fuel system for an engine.

[0194] In F1, a system comprises: a fuel line configured to distribute fuel to a fuel injection system; A hydrodynamic separation element comprising one or more hydrodynamic separators, each defining a curved microfluidic channel for separating particles in the fuel, wherein each microfluidic channel defines: a seamless communication input with the fuel line to receive fuel, and Petition 870230102574, dated 11 / 22 / 2023, pages 80 / 110 73 / 78 an outlet comprising a first flow branch in fluid communication with the fuel line to supply fuel to the fuel injection system and a second flow branch to receive particles in a specific size range.

[0195] In the F2 mode, a system comprises the system according to the F1 mode, wherein the particles comprise water droplets dispersed in the fuel.

[0196] In the F3 embodiment, a system comprises the system according to the F1 or F2 Embodiments, and further comprises a fuel tank in fluid communication with each inlet and in fluid communication with each second flow branch.

[0197] In the F4 embodiment, a system comprises the system according to any previous F Embodiment, but further comprises a fuel filter configured to filter gasoline or diesel fuel particles positioned along the fuel line.

[0198] In embodiment F5, a system comprises the system according to any previous Embodiment F, further comprising a fuel pump in fluid communication with the fuel line, wherein the fuel pump is configured to supply fuel flow to the fuel injector system along the fuel line, wherein the fuel injector system comprises a common high-pressure conduit.

[0199] Some forms refer to a bulk fuel system.

[0200] In the G1 modality, a system comprises: A fuel line configured to distribute fuel from a bulk fuel storage tank to a vehicle fuel tank. Petition 870230102574, dated 11 / 22 / 2023, pp. 81 / 110 74 / 78 a hydrodynamic separation element comprising one or more hydrodynamic separators, each defining a curved microfluidic channel for separating particles in the fuel, wherein each microfluidic channel defines: an inlet in fluid communication with the fuel line to receive fuel, and an outlet comprising a first flow branch in fluid communication with the fuel line to supply fuel to the vehicle's fuel tank and a second flow branch to receive particles within a specific size range.

[0201] In the G2 modality, a system comprises the system according to the G1 modality, and also includes the bulk fuel storage tank for storing fuel in fluid communication with the inlet and, optionally, in fluid communication with the second flow branch.

[0202] In the G3 modality, a system comprises the system according to Modalities G1 or G2, and also includes a secondary storage tank for storing fuel in fluid communication with the second flow branch.

[0203] In the G4 modality, a system comprises the system according to any previous G Modality, but further comprises a fuel filter configured to filter gasoline or diesel fuel particles positioned along the fuel line.

[0204] In the G5 embodiment, a system comprises the system according to any previous G Embodiment, but further comprises a fuel pump in fluid communication with the fuel line, wherein the fuel pump is configured to supply fuel flow to the vehicle fuel tank along the fuel line. Petition 870230102574, dated 11 / 22 / 2023, pages 82 / 110 75 / 78

[0205] Some embodiments refer to a hydraulic particulate filter.

[0206] In H1 mode, a system comprises: A hydraulic fluid line configured to distribute hydraulic fluid from a hydraulic pump to a hydraulic component. A hydrodynamic separation element comprising one or more hydrodynamic separators, each defining a curved microfluidic channel for separating particles in the hydraulic fluid, wherein each microfluidic channel defines: an inlet in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump, and an outlet comprising a first flow branch in fluid communication with the hydraulic fluid line to supply hydraulic fluid to the hydraulic component and a second flow branch to receive particles within a specific size range.

[0207] In embodiment H2, a system comprises the system according to Embodiment H1, but further comprises a hydraulic fluid filter for filtering hydraulic fluid particles positioned along a hydraulic fluid return line in fluid communication between the second flow branch and a hydraulic fluid reservoir, wherein the hydraulic fluid reservoir is in fluid communication with a hydraulic pump inlet.

[0208] Some modalities refer to the intensification of hydraulic deaeration.

[0209] In modality I1, a system comprises: A hydraulic fluid return line configured to distribute hydraulic fluid from a hydraulic component to a hydraulic pump. A hydrodynamic separation element comprising one or more hydrodynamic separators, each defining a curved microfluidic channel for separating particles in the hydraulic fluid, wherein each microfluidic channel defines: Petition 870230102574, dated 11 / 22 / 2023, pp. 83 / 110 76 / 78 an inlet in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump, and an outlet comprising a first flow branch in fluid communication with the hydraulic fluid line to supply hydraulic fluid to the hydraulic pump and a second flow branch to receive particles in a specific size range.

[0210] In embodiment I2, a system comprises the system according to Embodiment I1, wherein the particles comprise air bubbles.

[0211] In embodiment I3, a system comprises the system according to Embodiment I2, and further comprises a nucleation filter for nucleating air bubbles in the hydraulic fluid in fluid communication between the hydraulic component and the inlet.

[0212] In modality I4, a system comprises the system according to Modality I3, and also includes: a main reservoir in fluid communication between the first flow branch and the hydraulic pump; and a settling reservoir in fluid communication between the second flow branch and the main reservoir.

[0213] Thus, various embodiments of systems and methods for separating particles in hydrocarbon fluids are disclosed. Although reference is made in this document to the set of drawings that form part of this disclosure, at least one of common skill in the art will recognize that various adaptations and modifications of the embodiments described in this document are within, or do not deviate from, the scope of this disclosure. For example, aspects of the embodiments described in this document can be combined in various ways with one another. Therefore, it should be understood that, within the scope Petition 870230102574, dated 11 / 22 / 2023, pp. 84 / 110 77 / 78 of the appended claims, the claimed invention may be practiced in a manner other than explicitly described in this document.

[0214] All references and publications mentioned in this document are expressly incorporated herein by reference in their entirety for all purposes, except where any aspect directly contradicts this disclosure.

[0215] All scientific and technical terms used in this document have meanings commonly used in the art, unless otherwise specified. The definitions provided in this document are for the purpose of facilitating the understanding of certain terms frequently used in this document and are not intended to limit the scope of this disclosure.

[0216] Unless otherwise indicated, all numbers expressing sizes, quantities, and physical properties of features used in the specification and claims may be understood as being modified by the term exactly or approximately. Therefore, unless otherwise indicated, the numerical parameters set forth in the above specification and appended claims are approximations that may vary depending on the desired properties that those skilled in the art seek to obtain using the teachings disclosed herein or, for example, within typical ranges of experimental error.

[0217] The recitation of numerical ranges by periods includes all numbers included in that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range. In this document, the terms up to or not greater than a number (e.g., up to 50) include the number (e.g., 50) and the term not less than a number (e.g., not less than 5) includes the number (e.g., 5). Petition 870230102574, dated 11 / 22 / 2023, pp. 85 / 110 78 / 78

[0218] Terms related to orientation, such as “upstream” and “downstream,” are used to describe the relative positions of components and are not intended to limit the absolute orientation of the modalities contemplated.

[0219] The terms coupled or connected refer to elements that are fixed to each other directly (in direct contact with each other) or indirectly (that have one or more elements between them that fix the two elements). Either term can be modified by operatively and operationally, which can be used interchangeably, to describe that the coupling or connection is configured to allow the components to interact to perform the functionality.

[0220] As used in this document, the term configured for may be used interchangeably with the terms adapted for or structured for, except where the content in this disclosure clearly indicates otherwise.

[0221] The term “or” is generally used in its inclusive sense, for example, to mean “and / or”, unless the context clearly indicates otherwise. The term “and / or” means one or all of the listed elements or a combination of at least two of the listed elements.

[0222] The expressions at least one of, includes at least one of and one or more of followed by a list refer to any of the items in the list and any combination of two or more items in the list. Petition 870230102574, dated 11 / 22 / 2023, pp. 86 / 110

Claims

1 / 4 CLAIMS 1. System comprising: a hydrodynamic separation element comprising one or more hydrodynamic separators (260), each defining a curved microfluidic channel (241) in fluid communication, each microfluidic channel (241) defining: an inlet (242) configured to receive a first fluid (208) and particles (210) dispersed in the first fluid (208), the particles (210) having a different composition from the first fluid (208), and an outlet (244) comprising a first flow branch (246) and a second flow branch (248), wherein, at a predetermined flow rate,Each microfluidic channel (241) is configured to direct any particles exceeding a corresponding size limit to the second flow branch and any remaining particles to either the first flow branch (246) or the second flow branch (248); a particle sensor (112) positioned along one or more hydrodynamic separators (260) configured to provide signal data representing a signal corresponding to the first fluid (208) and the particles (210) in the first fluid (208); CHARACTERIZED in that the system comprises a controller (110) operationally coupled to the particle sensor (112) to receive the signal data and operationally coupled to a fluid pump (114) in fluid communication with the hydrodynamic separation element,the controller (110) is configured to: control the fluid pump (114) to direct the first fluid (208) through the hydrodynamic separation element, Petition 870240098259, 11 / 18 / 2024, page 10 / 24 2 / 4 determine if a limit level of particles (210) is present in at least one microfluidic channel (241) based on signal data from the particle sensor (112), and control a flow rate through the hydrodynamic separation element in response to determining that the limit level of particles (210) is present in at least one microfluidic channel (241), to direct the first fluid (208) at the predetermined flow rate through the hydrodynamic separation element to direct any particles (210) exceeding the corresponding limit size to the second flow branch (248) of at least one microfluidic channel (241),wherein the system further comprises a source reservoir (104) in fluid communication with the inlet (242) and the second flow branch (248), wherein the first fluid (208) and particles are pumpable from the source reservoir (104) to the hydrodynamic separation element and back selectively to the source reservoir (104) via the second flow branch (248).

2. System according to claim 1, CHARACTERIZED in that the particle sensor (112) comprises: a light source (202) configured to direct a light beam (214) in a frequency band along a path through at least one hydrodynamic separator (260), wherein the frequency band is selected so as to have an absorbance by the particles (210) different from the absorbance by the first fluid (208); an aperture element (218) that defines a light aperture (204) positioned in the path of the light beam (214) coming from the light source (202); and Petition 870240098259, dated 11 / 18 / 2024, p.11 / 24 3 / 4 a light detector (206) positioned to receive the light beam (214) in a catchment area (216) after passing through at least one hydrodynamic separator (260) and the light aperture (204), wherein the light detector (206) is configured to provide signal data representing an amount of light in the frequency band that remains after passing through at least one hydrodynamic separator (260).

3. System according to claim 1, CHARACTERIZED in that the particle sensor (112) comprises a capacitance sensor.

4. System, according to any one of claims 1 to 3, CHARACTERIZED in that the controller (110) is further configured to determine a quantity of a second fluid in the form of droplets per unit volume of the first fluid (208) based on signal data.

5. System according to claim 4, CHARACTERIZED in that the controller (110) is configured to determine a droplet rate or a droplet size of one or more droplets of the second fluid dispersed in the flow of the first fluid (208) based on signal data.

6. System according to claim 5, CHARACTERIZED in that the controller (110) is configured to determine the droplet rate or droplet size based on at least one of: a magnitude of a pulse contained within the signal data, a pulse width contained within the signal data, a first signal threshold level to detect a minimum-sized droplet in a catchment area (216), a second signal threshold level to detect a droplet that fills the catchment area (216), and a signal threshold level overrun rate. Petition 870240098259, dated 11 / 18 / 2024, page 12 / 24 4 / 4 7. System according to claim 6, CHARACTERIZED in that the controller (110) is further configured to determine at least one of: a quantity of the second fluid in the form of droplets per unit volume of the first fluid (208) based on the droplet rate and droplet size; the droplet size based on the magnitude of a pulse contained within the signal data in response to the signal that does not cross the second signal threshold level; the droplet size based on the width of a pulse contained within the signal data in response to the signal that crosses the second signal threshold level; and the droplet size based on the droplet rate. Petition 870240098259, dated 11 / 18 / 2024, p. 13 / 24

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