System and method for separating particles in a fluid

Abstract

The separation element comprising the microfluidic channel can use a hydraulic separator or a flow path selection element to separate particles in the fluid. A particle sensor can be used to count the particles in each microfluidic channel. A unique orifice pattern can be used to promote the use of a shared particle sensor in multiple microfluidic channels. The separation element can be used in various systems such as engine fuel systems, bulk fuel systems, hydraulic particle filters, and hydraulic degassing enhancers.

Description

[0001] This application claims the benefit of U.S. Provisional Application No. 62 / 942,009, filed on November 29, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates to separating particles. In particular, the present disclosure relates to separating particles in a fluid.

[0003] In certain systems, such as in engine fuel systems, bulk fuel systems, hydraulic systems, or other systems that handle or store fluids, particles dispersed in the fluid can cause problems. For example, water particles (or water droplets) in the fuel can cause problems in the engine fuel system of an internal combustion engine. Water in the fuel can damage the fuel injector due to corrosion or vaporization during the combustion process. Damage to the injector can cause various problems in the operation of the engine, such as failure to meet jurisdictional emission standards. Damage to the fuel injector may require repair or maintenance. The cost of reduced operating time can be particularly high for commercial or industrial vehicles. In general, gas, liquid, or solid particles dispersed in the fluid can cause problems in various fluid systems (such as bulk fuel systems, hydraulic systems, etc.). Conventional fluid filters capture particles in the media structure. Over time, the media structure may become clogged, requiring maintenance or replacement of the filter. Summary of the invention

[0004] The technology of the present disclosure generally relates to certain particles in the concentrated fluid in various fluid systems and such particles are separated from the fluid or from particles of other sizes.Usually, the fluid system may include a particle separation element (such as a hydraulic separation element) to concentrate the particles in a specific size range. The particle separation element may include an inlet and an outlet with at least two flow branches. The particles of a specific size range may be concentrated in a flow branch in two flow branches. In certain embodiments, particles that exceed a threshold size range are concentrated in a flow branch in two flow branches. Any remaining particles may flow through these at least two flow branches. In certain embodiments, the particle separation element may be used to supplement or replace a fluid filter.

[0005] In one aspect, the present disclosure relates to a hydroseparator. A system includes a hydroseparator element having one or more hydroseparators, each of which defines a curved microfluidic channel in fluid communication. Each microfluidic channel defines an inlet and an outlet, the inlet being configured to receive a fluid and particles dispersed in the fluid, wherein the particles have a composition different from that of the fluid, and the outlet comprising a first flow branch and a second flow branch. At a predetermined flow rate, each microfluidic channel is configured to guide any particles exceeding a corresponding threshold size into the second flow branch, and to guide any remaining particles into the first flow branch and the second flow branch. The system also includes a particle sensor positioned along one or more hydroseparators, the particle sensor being configured to provide signal data representing a signal corresponding to a fluid and particles in the fluid. The system further includes a controller operably connected to the particle sensor to receive signal data and operably connected to a fluid pump in fluid communication with the hydroseparator element. The controller is configured to: control the fluid pump to direct the fluid through the hydraulic separation element, determine whether there is a threshold level of particles in the at least one microfluidic channel based on the signal data from the particle sensor, and in response to determining that there is a threshold level of particles in the at least one microfluidic channel, control the flow through the hydraulic separation element to direct the fluid through the hydraulic separation element at a predetermined flow rate, thereby concentrating any particles exceeding the corresponding threshold size into a second flow branch of the at least one microfluidic channel.

[0006] On the other hand, 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 connected in parallel fluid. Each microfluidic channel defines an inlet and an outlet, the inlet is configured to receive a fluid and particles dispersed in the fluid, wherein the particles have a different composition from the fluid, and the outlet includes a first flow branch and a second flow branch. The system also includes a flow route selection element, which is positioned along at least one flow branch of at least one outlet. The system further includes a particle sensor, which is positioned along one or more microfluidic channels, and the particle sensor is configured to provide signal data representing a signal corresponding to the fluid and the particles dispersed in the fluid. The system includes a controller, which is operably connected to at least one flow route selection element and is operably connected to the particle sensor to receive the signal data. The controller is configured to: control the flow route selection element to direct the fluid flow to a first flow branch of at least one outlet of the at least one microfluidic channel, determine whether a threshold level of particles exists in the at least one microfluidic channel based on signal data from the particle sensor, and in response to determining that the threshold level of particles exists in the at least one microfluidic channel, control the flow route selection element to direct the fluid flow to a second flow branch of the at least one microfluidic channel.

[0007] On the other hand, the present disclosure relates to a particle sorter. A system includes a hydraulic separation element, which includes a plurality of hydraulic separators connected in series fluid, the plurality of hydraulic separators including at least a first hydraulic separator and a second hydraulic separator, each hydraulic separator defining a curved microfluidic separation channel to separate particles of different size ranges. Each microfluidic separation channel defines an inlet and an outlet, the inlet being configured to receive a fluid containing particles, the outlet including a first flow branch and a second flow branch. At a specific flow rate, each microfluidic separation channel is configured to guide any particles exceeding a corresponding threshold size into the second flow branch and guide any remaining particles into the first flow branch and the second flow branch, wherein the first flow branch of the first hydraulic separator is in fluid communication with the inlet of the second hydraulic separator. The system also includes a microfluidic sensing element in fluid communication with the hydraulic separation element. The microfluidic sensing element includes a plurality of microfluidic sensing channels, each of which is in fluid communication with different flow branches of the hydraulic separation element. The multiple microfluidic sensing channels include at least: a first microfluidic sensing channel, which is fluidically connected to the second flow branch of the first hydraulic separator to receive any particles exceeding a first threshold size, and a second microfluidic sensing channel, which is fluidically connected to the second flow branch of the second hydraulic separator to receive any particles exceeding a second threshold size, wherein the first threshold size is greater than the second threshold size.

[0008] In yet another aspect, the disclosure relates to an orifice pattern. A system includes a plurality of microfluidic sensing channels, each of which is configured to receive a flow of a fluid and particles dispersed in the fluid. The particles have a composition different from that of the fluid. The system also includes a light source configured to guide a light beam of a certain frequency band along a path through the plurality of microfluidic sensing channels. The frequency band is selected so that the particles and the fluid have different absorbances. The system further includes an aperture element defining a plurality of light holes, which have different groups of light holes aligned with each microfluidic sensing channel. Each group of light holes defines a unique spacing pattern along the corresponding microfluidic sensing channel. The system also includes a light detector positioned to receive the light beam in a sensing region after the light beam passes through the plurality of light holes of the aperture element and passes through the plurality of microfluidic sensing channels. The light detector is configured to provide a signal representing the amount of light of the frequency band remaining after passing through the plurality of microfluidic sensing channels. Further, the system includes a controller operably connected to the light detector and configured to: determine signal data based on the signal from the light detector, determine whether a particle has passed through a sensing region based on the signal data, and determine a unique spacing pattern associated with a particle passing through the sensing region based on the signal data.

[0009] In yet another aspect, the present disclosure relates to water droplet detection.A system includes a system according to the present disclosure, wherein the particles include a second fluid different from the fluid.

[0010] In another aspect, the present disclosure relates to an engine fuel system. A system includes a fuel line configured to deliver fuel to a fuel injector system. The system also includes a hydraulic separation element having one or more hydraulic separators, each hydraulic separator defining a curved microfluidic channel to separate particles in the fuel. Each microfluidic channel defines an inlet and an outlet, the inlet being in fluid communication with the fuel line to receive the fuel, the outlet including a first flow branch in fluid communication with the fuel line to provide fuel to the fuel injector system, and a second flow branch receiving particles within a specific size range.

[0011] In another aspect, the present disclosure relates to a bulk fuel system. A system includes a fuel line configured to deliver fuel from a bulk fuel storage tank to a vehicle fuel tank. The system also includes a hydraulic separation element having one or more hydraulic separators, each hydraulic separator defining a tortuous microfluidic channel to separate particles in the fuel. Each microfluidic channel defines an inlet and an outlet, the inlet being in fluid communication with the fuel line to receive the fuel, the outlet including a first flow branch in fluid communication with the fuel line to provide fuel to the vehicle fuel tank, and a second flow branch receiving particles within a specific size range.

[0012] In yet another aspect, the present disclosure relates to a hydraulic particulate filter. A system includes a hydraulic fluid line configured to deliver hydraulic fluid from a hydraulic pump to a hydraulic component. The system also includes a hydraulic separation element having one or more hydraulic separators, each hydraulic separator defining a tortuous microfluidic channel to separate particles in the hydraulic fluid. Each microfluidic channel defines an inlet and an outlet, the inlet being in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump, the outlet including a first flow branch in fluid communication with the hydraulic fluid line to provide hydraulic fluid to the hydraulic component, and a second flow branch receiving particles within a specific size range.

[0013] In yet another aspect, the present disclosure relates to enhanced hydraulic degassing. A system includes a hydraulic fluid return line configured to deliver hydraulic fluid from the hydraulic component to a hydraulic pump. The system also includes a hydraulic separation element having one or more hydraulic separators, each hydraulic separator defining a tortuous microfluidic channel to separate particles in the hydraulic fluid. Each microfluidic channel defines an inlet and an outlet, the inlet being in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump, the outlet including a first flow branch in fluid communication with the hydraulic fluid line to provide hydraulic fluid to the hydraulic pump, and a second flow branch receiving particles within a specific size range. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Various embodiments of the present disclosure are shown in the accompanying drawings, which are summarized as follows:

[0015] Figure 1 is a conceptual diagram illustrating one example of a fluid system according to the present disclosure, the fluid system including a particle separation element configured to receive a fluid flow from a fluid source.

[0016] Figure 2 is a conceptual diagram showing an example of a fluid system that can be used with Figure 1 The particle separation element is used together with the particle separation element to process the fuel on the machine.

[0017] Figure 3 is a conceptual diagram showing an example of a fluid system that can be used with Figure 1 Used together with a particle separation element to process bulk fuel.

[0018] Figure 4 is a conceptual diagram showing an example of a fluid system that can be used with Figure 1 The particle separation element is used together with the hydraulic fluid to convey the hydraulic fluid.

[0019] Figure 5 is a conceptual diagram showing an example of a fluid system that can be used with Figure 1 The particle separation element is used to degas the hydraulic fluid.

[0020] Figure 6 It is shown that it can be used for Figure 1 A conceptual diagram of an example of an optical or light-based particle sensor in a particle sensor.

[0021] Figure 7 It is shown that the microfluidic channel is used Figure 1 A conceptual diagram of an example of an arrangement of a particle sensor.

[0022] Figure 8It is shown that the microfluidic channel is used in combination with Figure 1 A conceptual diagram of another example of an arrangement of a particle sensor.

[0023] Figures 9 and 10 It shows that Figure 1 A conceptual diagram of another arrangement of a particle sensor for use with a particle separation element and a microfluidic sensing element.

[0024] FIG. 11A to FIG. 11B is a conceptual diagram showing an example of a technology that can be used with Figure 1 The particle sensors are used together to count the number of particles in multiple microfluidic channels using a shared light detector.

[0025] Fig.12 is a conceptual diagram showing an example of a fluid system that can be used with Figure 1 Used together with a particle separation element to remove particles.

[0026] FIG. 13A to FIG. 13D Image and graph showing the hydroseparator device and pixel intensity versus channel position, respectively.

[0027] Fig.14 It is shown around FIG. 13A to FIG. 13D Conceptual diagram of the relative positions of the angles of the hydroseparator device.

[0028] Fig.15 It is shown FIG. 13A to FIG. 13D Graph of percent concentration versus channel length for a hydroseparator device. DETAILED DESCRIPTION

[0029] In the following detailed description, reference is made to several specific embodiments. It should be understood that other embodiments are contemplated and can be formed without departing from the scope or spirit of the present disclosure. Therefore, the following detailed description should not be understood in a limiting sense.

[0030] The present disclosure provides a technology that makes some particles in the fluid concentrate and these particles are separated from the particles of fluid or other sizes in various fluid systems.Usually, the fluid system can include a particle separation element (such as a hydraulic separation element) to concentrate the particles in a specific size range.The particle separation element can include an inlet and an outlet with at least two flow branches.The particles of a specific size range can be concentrated in a flow branch in two flow branches.In certain embodiments, the particles that exceed the threshold size range are concentrated in a flow branch in two flow branches.Any remaining particles can flow through these at least two flow branches.In certain embodiments, the particle separation element can be used to supplement or replace a fluid filter.

[0031] A particle separation element (which may include a hydraulic separation element) can be used as a substitute or supplement to a filter. In particular, a particle separation element can be used to gather particles above a critical size into a portion of a fluid flow. This portion of the fluid flow can be removed from the system, thereby removing most of the particles that exceed the threshold size. In some cases, this may replace some or all of the functions of the filter. The performance of the particle separation element does not change over time and does not require regular replacement. In some embodiments, a filter can be used downstream of the particle separation element to remove particles below the threshold size. Further, in some embodiments, the particles concentrated by the particle separation element are filtered. This can be done at a lower surface velocity than a system without a particle separation element, and therefore makes the filter pressure drop lower and the filter life longer.

[0032] Particle separation elements (which may include hydraulic separation elements) may also be used to sort particles of different sizes. In some applications, a threshold size may be determined. The particle separation element may be designed to aggregate particles above the threshold size into the aggregated fluid portion of a fluid stream. The aggregated portion of the fluid stream may be removed from the system. This technology may be used to aggregate particles to perform particle counting. This technology may also be used to separate different types of particles or aggregate certain materials to collect.

[0033] Microfluidic particle sensors or microfluidic sensing elements can be used to detect individual pollutants in fluids (such as liquid flows). 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 streamlines based on particle size. For example, this can be done by Dean Flow Separation. Once the particles are in streamlines based on their particle size, these streamlines are transmitted to different sensing channels of the microfluidic sensing element. The sensing channel is associated with a particle sensor that counts the number of particles. By understanding the number of particles in each sensing channel, an approximate particle size distribution can be determined. The sensor can be an optical sensor, a capacitive sensor, a magnetic sensor, or other sensors. Alternatively, the particle sensor can include only a microfluidic channel and a sensor. Relative to other technologies, such as Mie scattering, the use of microfluidic channels can increase sensitivity to individual pollutants. Signal processing can also be used to identify pollutant types.

[0034] Further, a particle separation element, which may include a hydraulic separation element, may be used to selectively remove particle waste. In some cases, only particles above a certain size may be removed from the system. Uses for selective particle waste removal may include, but are not limited to, removing or agglomerating fat from milk (fat is typically in clumps of 0.1 to 15 microns), removing or agglomerating orange juice pulp, removing contaminants from semiconductor processing fluids, and removing ink agglomerates from industrial ink processing. In one example related to wafer polishing slurry, a particle separation element may be designed to remove particles above a threshold size, which may be agglomerates or impurities, while allowing particles below the threshold size to pass.

[0035] definition

[0036] Particles

[0037] As used herein, the term "particles" refers to discrete amounts of material that can be dispersed in different fluids. Non-limiting examples of materials that may form particles include dirt, metals, air bubbles, and water droplets. In one particular example, water droplets may be dispersed in a hydrocarbon fluid (such as gasoline or diesel fuel) to form an emulsion. In another example, air bubbles may be dispersed in a hydraulic fluid.

[0038] Upstream / Downstream

[0039] As used herein, the term "downstream" refers to the direction along the flow of a fluid. The term "upstream" refers to the direction opposite to downstream, or the direction opposite to the flow of a fluid.

[0040] Microfluidic channels

[0041] As used herein, the term "microfluidic channel" refers to a channel having at least one dimension less than 1 mm (1000 microns). A microfluidic channel can have a channel width less than 1000 microns, a channel height (or depth) less than 1000 microns, or both. In some embodiments, for applications with higher flow rates, at least one dimension of a microfluidic channel can be greater than 1 mm. In some embodiments, at least one dimension of a microfluidic channel is greater than or equal to 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm, or is less than or equal to 10, 9, 8, 7, 6, 5, 4, 3, or 2 mm. Typically, a channel can have any suitable length to provide a suitable pressure drop balanced with a suitable particle concentration.

[0042] A microfluidic channel can be described by a cross-sectional area width x height. In some embodiments, the cross-sectional area of ​​a microfluidic channel can be less than 10, 9, 8, 7, 6, 5, 4, 3, or 2 square millimeters.

[0043] Microfluidic channels can also be described in terms of hydraulic diameter. For example, for a microfluidic channel with a rectangular cross-section, the hydraulic diameter can be calculated as follows:

[0044]

[0045] Among them, D H is the hydraulic diameter. Other cross-sectional shapes can be calculated according to techniques known to those of ordinary skill in the art having the benefit of this disclosure. In some embodiments, the hydraulic diameter of the microfluidic channel can be less than 5, 4, 3, 2, or 1 mm. In at least one embodiment, the hydraulic diameter of the microfluidic channel of the microfluidic channel can be less than 1 mm.

[0046] Hydraulic separator

[0047] As used herein, the term "hydraulic separator" refers to a curved fluid channel, which includes at least an inlet and an outlet, the inlet being used to receive a fluid flow, and the outlet including at least two branches separating the fluid flow. The fluid channel can be a microfluidic channel. The inlet can receive a fluid that can contain particles of various sizes. At a specific flow rate, the hydrodynamic separator is configured to concentrate any particles exceeding a threshold size into one branch. Any remaining particles will not be concentrated in the fluid flow. The remaining particles can be separated between all branches, for example, based on the volume fraction or outlet flow ratio associated with each branch. The hydrodynamic separator can be designed based on at least one or more of the following parameters: Dean number, Reynolds number, hydraulic diameter, radius of curvature, target flow, target pressure drop, critical particle size, fluid viscosity, operating temperature (may affect fluid viscosity), outlet flow ratio or any combination of these parameters. The hydrodynamic separator can also be described as a Dean flow separator.

[0048] Typically, a hydroseparator comprises a curved microfluidic channel, which is designed to concentrate particles exceeding a threshold size onto a curved inner wall. 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) that is designed to concentrate particles in a known fluid within a specific flow or flow range. Then, by removing a portion of fluid near the inner wall, the concentrated particles near the inner wall can be removed from the system. In other embodiments, depending on the geometry and operating conditions of the device, particles and waste streams can alternatively be concentrated near the outer wall. The design of the device may depend on application flow, fluid properties (such as viscosity and density) and threshold particle size. A hydroseparator can serve as a filter or pre-filter in the system.

[0049] Curved microfluidic channels can be used to concentrate particles of a predetermined size under appropriate flow conditions. In a curved channel or pipe under laminar flow conditions, the inertia of the fluid creates a pressure gradient across the channel. To mitigate the pressure gradient, two spiral flows may form, called Dean flows (sometimes also called secondary flows). The Dean flow may create resistance to any particles in the fluid. In larger channels, particles can sweep along the channel in a spiral motion. When the channel becomes smaller, such as in a microfluidic channel, the Dean flow can be balanced with two additional forces so that particles can be captured and concentrated on the inner walls of the curved channel. These forces can be described as shear-induced lift, which causes lift toward the wall, and wall-induced lift, which pushes the particles away from the wall as the particles approach the wall due to the restriction of the fluid flow. Particles can be concentrated into specific streamlines within a curved channel. Concentrating particles in this way can be called hydraulic separation or Dean flow separation.

[0050] Flow routing element

[0051] As used herein, a "flow routing element" refers to a component configured to allow for selective routing of a fluid flow exiting a fluid channel. Non-limiting examples of components of a flow routing element include valves or solenoids. In one example, the flow routing element may include one or more valves configured to divert the flow to one or more branches in any suitable manner.

[0052] Dean number

[0053] The Dean number describes the behavior of a fluid in a curved pipe and accounts for the inertial, centripetal, and viscous forces acting on the fluid. In various embodiments, a system is configured to have a Dean number between 5 and 25. The Dean number is defined as:

[0054]

[0055] Where Re is the Reynolds number and Rc is the radius of curvature of the fluid channel.

[0056] Reynolds number

[0057] The Reynolds number describes the ratio of inertial forces to viscous forces and is defined as:

[0058]

[0059] Where ρ is the fluid density, U is the average fluid velocity, and μ is the dynamic viscosity of the fluid.

[0060] Reference will now be made to the accompanying drawings, which depict one or more aspects described in the present disclosure. However, it should be understood that other aspects not depicted in the accompanying drawings fall within the scope of the present disclosure. Similar numbers used in the figures refer to similar parts, steps, etc. However, it should be understood that the use of reference numerals to refer to elements in a given figure is not intended to limit the elements in another figure marked with the same reference numeral. In addition, the use of different reference numerals to refer to elements in different figures is not intended to indicate that the elements referred to differently cannot be the same or similar.

[0061] Figure 1 1 is a conceptual diagram of an example of a fluid system 100, which includes a particle separation element 102 configured to receive a fluid flow from a fluid source 104. The fluid system 100 can be a system of any suitable type 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 can contain particles. The particle separation element 102 can be used as a filter to facilitate the removal of particles of a specific size range from the fluid. For example, particles that are considered to be pollutants or waste can be removed. Additionally or alternatively, the particle separation element 102 can be used to facilitate the sorting of particles of different sizes. The sorting of particles of different sizes can allow the fluid system 100 to determine how many particles there are in different size ranges.

[0062] The particle separation element 102 can be fluidly coupled between a fluid source 104 and a fluid destination, such as 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 fluid, such as fuel consumed by an engine. The fluid destination 108 can be a component of the fluid system 100 that uses fluid and returns fluid to the fluid source 104, such as hydraulic fluid used in a hydraulic piston. The particle separation element 102 can remove particles of a specific size range from the fluid before providing the fluid to one of the fluid destinations 106, 108.

[0063] The particle separation element 102 may include any suitable components that can be used to remove particles from a fluid or to sort particles from a fluid. In some embodiments, the particle separation element 102 includes a hydraulic separation element. Typically, the particle separation element 102 (which may include a hydraulic separation element) will not be loaded with particles and will not change performance over time or require regular replacement.

[0064] 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 of the hydrodynamic separators may be designed to provide a target pressure drop.

[0065] In some embodiments, the particle separation element 102 includes a flow routing element. The flow routing element may be disposed in an outlet of the particle separation element 102. The flow routing element may include one or more valves or solenoids to divert the fluid flow.

[0066] Typically, the particle separation element 102 includes an outlet with at least two different branches. The fluid flow can be split between the different branches. In some embodiments, using a hydraulic separation element, all particles within a specific size range can be concentrated into one of the branches. Each branch may be associated with particles of a different size range (see Figures 9 and 10 ).

[0067] Each branch may be directed to, or in fluid communication with, a different fluid destination. In some embodiments, one branch may be directed to fluid destination 106 and another branch may be directed to fluid destination 108.

[0068] The fluid pump 114 can be used to control the flow of fluid through the particle separation element 102. The fluid pump 114 can be positioned at any suitable position relative to the particle separation element 102 (such as upstream, downstream, or integrated with the particle separation element) to facilitate the control of the flow. In the illustrated embodiment, the fluid pump 114 is positioned upstream of the particle separation element 102.

[0069] The particle sensor 112 can be used to detect any particles in the fluid flow. The particle sensor 112 can be positioned at any suitable location relative to the particle separation element 102 (such as upstream, downstream, or integrated with the particle separation element) to facilitate the detection of certain particles. In some embodiments, the particle sensor 112 can be positioned between the inlet and outlet of the particle separation element 102. The particle sensor 112 can use any suitable type of mechanism to detect particles in the fluid. For example, the particle sensor 112 can include or be a light-based particle sensor 200 ( Figure 6 ) or capacitance-based sensors.

[0070] The microfluidic sensing element 116 can be used to sense particles of different sizes from one or more branches of the branch of the particle separation element 102. The microfluidic sensing element 116 is shown as being positioned downstream of the particle separation element 102. In some embodiments, the microfluidic sensing element 116 can be described as a part of the particle separation element 102. The microfluidic sensing element 116 can include one or more microfluidic sensing channels. In some embodiments, the microfluidic sensing channels are arranged in parallel. The channel length and arrangement of the microfluidic sensing channels can be designed to provide a target pressure drop and particle concentration.

[0071] Each microfluidic channel can be fluidly connected to one of the branches of the particle separation element 102. The microfluidic sensing element 116 can also include one or more particle sensors 112 to detect particles of different sizes that have been sorted by the particle separation element 102. The microfluidic sensing element 116 can also be used to determine whether the particle separation element 102 has successfully removed some or all particles within a specific size range. The microfluidic sensing element 116 can also include a flow path selection element. The flow path selection element can be used to facilitate the removal of particles within a specific size range.

[0072] The fluidic subsystem 120 may be defined as including one or more of the following: a particle separation element 102, a fluid pump 114, a microfluidic sensing element 116, and a controller 110. The controller 110 may be used to facilitate the various functions of the fluidic subsystem 120 described herein.

[0073] Various configurations of fluid system 100 are contemplated. Further configurations and non-limiting examples of various components of fluid system 100 are shown and described in greater detail herein.

[0074] In an example that can be described as a kidney-shaped loop filter (not shown), a fluid pump 114 can be used to provide a fluid flow from a fluid source 104 or a source reservoir flowing through a particle separation element 102, which can include a hydraulic separator element that returns the main flow to the fluid source 104 through the filter. The industrial system with liquid fluid can use a kidney-shaped loop filtration system to remove particles. The particle separation element 102 can be used between a fluid pump 114 and the filter. The particle separation element 102 can provide a primary outlet flow to the fluid source 104, and the secondary outlet flow containing some particles is returned to the filter, which can aggregate particles and minimize the fluid volume that needs to be filtered and reduce surface velocity, which can reduce the filter pressure drop.

[0075] One or more components described herein (such as controllers, sensors, detectors, or systems) may include a processor, such as a central processing unit (CPU), a computer, a logic array, or other device capable of directing data into and out of a component. A processor may include one or more computing devices having memory, processing, and communication hardware. A processor may include circuits for coupling various components of a controller together or coupling various components of a controller to other components operably coupled to the controller. The functions of a processor may be performed by hardware and / or as computer instructions on a non-transitory computer-readable storage medium.

[0076] 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 equivalent discrete 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 other discrete or integrated logic circuits. The functions attributed to the processor herein may be implemented as software, firmware, hardware, or any combination thereof.

[0077] In one or more embodiments, the functions of the processor can be implemented using one or more computer programs using a computing device, which may include one or more processors and / or memories. The program code and / or logic described herein can be applied to input data / information to perform the functions described herein and generate desired output data / information. The output data / information can be applied as input to one or more other devices and / or methods as described herein or applied in a known manner. In view of the above, it is apparent that the controller functions described herein can be implemented in any manner known to those skilled in the art.

[0078] Figure 2 1 is a conceptual diagram showing one example of a fluid system that can be used to process fuel on a machine using a particle separation element 102. The particle separation element 102 (which can include a hydrodynamic separator element) can be used on 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, a lift pump draws fluid from a fuel tank and pushes it to a high pressure common rail. Some fuel may be returned to the fuel tank from a fuel injector system through a fuel return line 128.

[0079] As shown, a fluid pump 114 (e.g., a fuel pump or lift pump) can be used to provide a fluid flow, such as fuel, from a fluid source 104 (e.g., a fuel tank) through the particle separation element 102 and through a main fuel line 122. The particle separation element 102 can provide a primary outlet flow along the main fuel line 122 to a fluid destination 106 (e.g., a fuel injector system that may include a high-pressure common rail) using a first flow branch 123, and a secondary outlet flow containing certain particles returned to the fluid source 104 along a second flow branch 124. Non-limiting examples of particles include dirt and water droplets.

[0080] 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 126 can be positioned downstream of the particle separation element 102 along the main fuel line 122. The filter 126 or fuel filter can be configured to filter particles from gasoline or diesel fuel. The fluid system 120 can 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 can be positioned along the second flow branch 124, or another filter 126 can also be positioned along the second flow branch, and the filter can filter particles at a lower flow rate and pressure drop.

[0081] The particle separation element 102 may be configured to remove particles having a diameter exceeding or larger than a certain threshold size from the main fuel line 122 while the fluid pump 114 provides fuel at a certain flow rate for engine operation and provides such particles to the second flow branch 124. Non-limiting examples of the certain threshold size include 1, 2, 5, 10, 15, or 20 microns.

[0082] The outlet of particle separation element 102 can be described as having two outlet flows: a "clean" outlet flow along the first flow branch 123 to the main fuel line 122, and a "dirty" outlet flow along the second flow branch 124. The clean outlet flow may not contain particles above the threshold size. The clean outlet flow can be transmitted to the filter 126, and finally arrives at the fluid destination 106, which is shown as the high-pressure common rail of the fuel injector system. The dirty outlet flow can contain most of the particles above the critical size. The dirty flow can be transmitted back to the fluid source 104 (shown as a fuel tank). In other embodiments, the dirty outlet flow can be combined with the fuel return line from the high-pressure common rail system. In other words, the second flow branch 124 can be fluidly connected to the fuel return line 128 before returning to the fluid source 104. The particle separation element 102 can have a mechanism for controlling the dirty outlet flow along the second flow branch 124, such as a valve (not shown), to facilitate operation when the filter pressure limit increases over time due to the load of the filter 126 along the first flow branch 123.

[0083] Figure 3 1 is a conceptual diagram illustrating one example of a fluid system that may be used to process bulk fuel using a particle separation element 102. The particle separation element 102, which may include a hydrodynamic separator element, may be used on a fluid system 140, such as a fuel distribution station, and may be used to remove particles before providing the fuel to a fluid destination 106, such as a vehicle.

[0084] As shown, a fluid pump 114 may be used to provide a fluid flow, such as fuel, from a fluid source 104 (e.g., a bulk fuel storage tank) through a particle separation element 102 to a main fuel line 142. The particle separation element 102 may use a first flow branch 143 to provide a primary outlet flow along the main fuel line 142 to a fluid destination 106 (e.g., a vehicle), and a secondary outlet flow containing certain particles for return to the fluid source 104 or delivery to a fluid destination 108 (e.g., a secondary storage tank) along a second flow branch 144. Non-limiting examples of particles include dirt and water droplets.

[0085] 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 particle separation element 102 along the main fuel line 122. The filter 146 or fuel filter can be configured to filter particles from gasoline or diesel fuel. The fluid system 120 can 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 can be positioned along the second flow branch 144, or another filter 146 can also be positioned along the second flow branch, and the filter can filter particles at a lower flow rate and pressure drop.

[0086] Particle separation element 102 may be configured to remove particles having diameters greater than a particular threshold size from main fuel line 122 while fluid pump 114 provides fuel at a particular flow rate appropriate for the fuel distribution station, and provide such particles to second flow branch 144 .

[0087] The outlet of particle separation element 102 can be described as having two outlet flows: a "clean" outlet flow to main fuel line 142 along first flow branch 143, and a "dirty" outlet flow along second flow branch 144. The clean outlet flow may not contain particles above threshold size. The clean outlet flow can be transmitted to filter 126, and finally arrive at fluid destination 106, which is shown as a high pressure common rail system. The dirty outlet flow can contain most of the particles above the critical size. The dirty outlet flow can be transmitted back to fluid source 104 (shown as a bulk fuel storage tank), or can be transmitted to fluid destination 108 (shown as a separate tank for containing dirty or contaminated fuel). The particle separation element 102 can have a mechanism for controlling the dirty outlet flow along second flow branch 144, such as a valve (not shown), to facilitate operation when the filter pressure limit increases over time due to the load of the filter 146 along the first flow branch 143.

[0088] Figure 4 1 is a conceptual diagram showing one example of a fluid system that may be used to deliver hydraulic fluid using a particle separation element 102. The particle separation element 102, which may include a hydrodynamic separator element, may be used on a fluid system 160, such as a hydraulic cylinder system, and may be used to remove particles before providing hydraulic fluid to a hydraulic component, such as an actuating cylinder, to protect the hydraulic component from particles.

[0089] As shown, fluid pump 114 (such as hydraulic pump) can be used to provide fluid flow from fluid source 104 (such as hydraulic fluid reservoir) flowing through particle separation element 102 to main fluid line 162. Fluid source 104 can be in fluid communication with the inlet of fluid pump 114. Particle separation element 102 can use first flow branch 163 to provide main outlet flow along main fluid line 162 to fluid destination 106 (such as hydraulic component, which can include actuator cylinder) and secondary outlet flow containing some particles, which is used to return to fluid source 104 along second flow branch 164. Non-limiting examples of particles include dirt, bubbles or micro-droplets. Fluid system 160 can also include a fluid return line 168 from fluid destination 106 to fluid source 104. Before returning to fluid source 104, second flow branch 164 can be fluidically coupled to fluid return line 168.

[0090] 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 hydraulic fluid filter 166 can be positioned downstream of the particle separation element 102 along the second flow branch 164, the fluid return line 168, or both. As shown, the second flow branch 164 and the fluid return line 168 merge before reaching the filter 166. The filter 166 can be in fluid communication with the fluid source 104.

[0091] The outlet of the particle separation element 102 can be described as having two outlet flows: a "clean" outlet flow along the first flow branch 163 to the main fluid line 162, and a "dirty" outlet flow along the second flow branch 164. The clean outlet flow can continue to flow to the fluid destination 106, which is shown as a hydraulic component. The dirty outlet flow can be combined with a fluid return line 168, which passes through a filter 166 before returning to the fluid source 104, which is shown as a fluid reservoir. The particle separation element 102 can be designed to operate within a range of temperatures, flows, and system configurations (e.g., extension of a hydraulic cylinder).

[0092] Figure 5 1 is a conceptual diagram illustrating one example of a fluid system that may be used to degas hydraulic fluid using a particle separation element 102. The particle separation element 102, which may include a hydrodynamic separator element, may be used on a fluid system 180, such as a hydraulic cylinder system, and may be used to remove nucleated bubbles before returning the hydraulic fluid to a fluid source 104, such as a main hydraulic fluid reservoir, to protect a fluid destination 106, such as a hydraulic component, from bubbles.

[0093] As shown, a fluid pump 114 (e.g., a hydraulic fluid pump) can be used to provide a fluid flow from a fluid source 104 (e.g., a main hydraulic fluid reservoir) along a main fluid line 182 to a fluid destination 106 (e.g., a hydraulic component), which can include an actuator cylinder. A return fluid flow can be provided from the fluid destination 106 to a nucleating filter 169 to nucleate bubbles in the fluid along a fluid return line 188. The particle separation element 102 can be positioned downstream of the nucleating filter 169. The nucleating filter 169 can be in fluid communication with the inlet of the particle separation element 102 and the fluid destination 106. The particle separation element 102 can use a first flow branch 183 to provide a primary outlet flow along a fluid return line 188 to the fluid source 104, and a secondary outlet flow (e.g., a settling reservoir or an aerated oil collection volume) to the fluid destination 108 along a second flow branch 184, the secondary outlet flow containing certain particles. The fluid destination 108 may be in fluid communication with the fluid source 104 with a restricted flow to allow the aerated hydraulic fluid to collect and settle.

[0094] The fluid in the hydraulic fluid system 180 is pressurized by the fluid pump 114. High-pressure fluid can dissolve more air. When the fluid is depressurized in the fluid return line 188, the fluid may become supersaturated with air, which may cause the nucleation and formation of bubbles in the fluid flow. The bubbles may have been removed before the fluid is drawn up again by the fluid pump 114. Bubbles reaching the fluid pump 114 may cause cavitation, which may be loud and may damage the fluid pump. A nucleation filter 169 may be used to nucleate and grow bubbles. The bubble-filled fluid may be conveyed through a particle separation element 102, which may include a hydraulic separator. Bubbles may gather along the second flow branch 184 into an "aerated return" outlet flow. The aerated return outlet flow may be returned to the fluid destination 108 or a settling reservoir in a volume that allows natural bubble settling. The fluid destination 108 may be a separate compartment in the same container as the fluid destination 106. The “main return flow” (without air bubbles) along the outlet flow is conveyed along the fluid return line 188 to the fluid destination 106 and is immediately available for use by the fluid system 180 .

[0095] Figure 6 is a conceptual diagram illustrating one example of an optical or light-based particle sensor 200 that may be used or utilized as the particle sensor 112 ( Figure 1). In general, any suitable type of particle sensor may be used, including, for example, the particle sensor described in PCT Application No. PCT / US2019 / 034809 filed on May 31, 2019, which is incorporated herein by reference. When particle sensor 200 is used to detect droplets of fluid, particle sensor 200 may be described as a droplet sensor. Particle sensor 200 may be operably coupled to controller 110 and optically coupled to microfluidic channel 201, which may be a particle separation element 102 ( Figure 1 ) is part of a hydrodynamic separator, or is a microfluidic sensing element 116 ( Figure 1 ) part.

[0096] As shown, the particle sensor 200 includes a light source 202, a light aperture 204, and a light detector 206. The controller 110 may be operably connected to the light detector 206, and may also be operably connected to the light source 202.

[0097] 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 droplets, bubbles, dirt, metal, in the flow of fluid 208 that may flow through the microfluidic channel 201.

[0098] Particles 210 may be dispersed in fluid 208 in microfluidic channel 201. For example, particles 210 may be suspended in fluid 208 as a separate phase, or made of 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 different fluid than fluid 208.

[0099] Typically, the microfluidic channel 201 is sized to receive one or more particles 210 at a time. In some embodiments, the cross-sectional area of ​​the microfluidic channel 201 is sized to receive one particle 210 of a predetermined size at a time. In particular, the cross-sectional area of ​​the microfluidic channel 201 can be approximately the same size as the cross-sectional area of ​​the particle 210, which can facilitate counting one particle 210 at a time to facilitate accurate counting and sizing of the particles 210.

[0100] The cross-sectional area can be defined as being orthogonal to the direction of the fluid 208 flow. In other words, the cross-sectional area can be described as being transverse to the longitudinal fluid 208 flow. The cross-sectional area can be defined as the channel height (or depth) multiplied by the channel width. Both the channel height and the channel width can be orthogonal to the direction of the fluid 208 flow. In some embodiments, the channel depth is less than or equal to the channel width. When particles flow through the microfluidic channel 201, using a relatively shallow channel depth can prevent particles 210 from accumulating between the light source 202 and the light detector 206, or hiding from each other, which increases the chance that each particle is detected.

[0101] light source

[0102] In the illustrated embodiment, the light source 202 is positioned outside of the microfluidic channel 201. At least one light hole 204 is positioned between the light source 202 and the light detector 206. In some embodiments, the light hole 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 hole 204 is positioned after the microfluidic channel 201, for example, between the microfluidic channel 201 and the light detector 206.

[0103] The light source 202 is configured to direct light 212 through the light aperture 204 to form a light beam 214. The light beam 214 is directed through 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 light beam axis extending through the microfluidic channel 201. The walls of the microfluidic channel 201 may be formed of a light transmissive material (at least for the light 212 provided by the light source 202).

[0104] The path of the light beam 214 intersecting the microfluidic channel 201 defines a sensing region 216, which can also be described as a sensing volume, in which the particle 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 can be positioned outside the microfluidic channel 201. When the particle 210 and the fluid 208 are in the sensing region 216, the light detector 206 can be used to determine the absorbance of the light beam 214 by the particle 210 and the fluid 208 to detect the particle 210, determine the size of the particle, or otherwise characterize the particle.

[0105] As used herein, 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 can be approximately equal to the width or depth of the microfluidic channel 201. The path length can be small to increase 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 microns. In one or more embodiments, the path length is less than or equal to 1000 microns.

[0106] The light source 202 is configured to generate light in a selected frequency band so that the particles 210 have a different absorbance than the fluid 208 in the selected frequency band. In one or more embodiments, for example when the liquid is water and the fluid 208 is a hydrocarbon fluid, the particles 210 have a higher absorbance than the fluid 208. For example, in a fuel system application, the light source 202 can generate light 212 at least in the near infrared (NIR) band. In some embodiments, the NIR light 212 may include an emission peak in the range of 1400 to 1600 nanometers, or at least include frequencies within this range. In particular, the NIR light 212 may include an emission peak centered at or near 1550 nanometers. In some embodiments, the NIR light 212 may include an emission peak in the range of at least 900 to 1100 nanometers, or at least include frequencies within this range. In particular, the NIR light 212 may include an emission peak centered at or near 1000 nanometers.

[0107] Light source 202 can include any suitable type of light source capable of providing light 212 in a selected frequency band. In some embodiments, light source 202 is a light emitting diode (LED). LED light source 202 can be a low power LED. In some embodiments, the LED light source is omnidirectional or emits in all directions from the light emitting junction. In some embodiments, the LED light source is mainly emitted in one direction. In some embodiments, light source 202 can be paired with or include a fiber optic cable that guides light to microfluidic channel 201. Light hole 204 can be used to allow narrow light beam 214 to pass through microfluidic channel 201, which can facilitate the elimination of noise or false signals caused by, for example, scattering and reflection.

[0108] The light hole 204 can be or include at least one opening in the hole element 218. As used herein, "hole" refers to an opening or void within the hole element 218. The light hole 204 can have a width that is sized 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 hole 204 is the same or substantially the same as the channel width of the microfluidic channel 201.

[0109] Additionally or alternatively, the size of the light hole 204 can be set relative to a predetermined particle size of interest. For example, in some embodiments, the width of the light hole 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, the width of the light hole 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.

[0110] The light hole 204 can have any suitable geometric shape. In some embodiments, the light hole 204 has a circular or rounded shape, such as a circle or an ellipse. In some embodiments, the light hole 204 has a polygonal shape, such as a triangle, a square, a trapezoid, or a rectangle. The light hole 204 can have a length that can extend in the same direction as the flow of the fluid 208. In one or more embodiments, the length of the light hole 204 can be the same or substantially the same as the width of the light hole 204.

[0111] Light detector

[0112] The light detector 206 can be any suitable type of photodetector that is sensitive to a selected frequency band, which can be a NIR frequency band. The light detector 206 is also configured to provide a signal representing the amount of light from the light beam 214 remaining after passing through the microfluidic channel 201. In particular, the light detector 206 can be configured to generate an electrical signal, such as a current signal, a voltage signal, or a power signal, in response to receiving light within a 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 within a frequency band from 1100 to 1700 nanometers. A Ge photodiode can have a peak sensitivity at 1550 nanometers. Si photodiodes can be used for visible light.

[0113] Controller

[0114] The controller 110 may be configured to detect, determine a size measurement of, or otherwise characterize one or more particles 210 dispersed in the stream of fluid 208 based on the signal from the light detector 206. In some embodiments, the controller 110 may be configured to detect one particle 210 dispersed in the stream of fluid 208 at a time, particularly a particle of a predetermined size.

[0115] Generally, when the particle 210 is a fluid, the particle may also be referred to as a droplet. When the particle 210 is a liquid, the signal may be used to determine the amount of liquid (eg, water) (excluding liquid dissolved in the fluid) per unit volume of the fluid 208 (eg, hydrocarbon fluid).

[0116] In some embodiments, the controller 110 is configured to determine the particle rate through the sensing region 216. For example, a change in absorbance detected based on the signal from the light detector 206 can indicate that the particle 210 is entering or leaving the sensing region 216. Alternatively or additionally, the controller 110 can be configured to determine the particle size. In some embodiments, the controller 110 can determine the particle rate or particle size based on at least one of the following: the amplitude of the pulse contained in the signal, the width of the pulse contained in the signal, the first threshold signal level for detecting the smallest size particle in the sensing region, the second threshold signal level for detecting particles filling the sensing region, and the threshold signal level crossing rate. When the particles are fluid, the controller 110 can determine the amount of particles 210 in the form of droplets per unit volume of the fluid 208, such as the particle concentration, based on the particle rate, the particle size, or both. In some applications, such as non-engine applications, when the particle rate is regular or substantially regular, the particle rate can be used to estimate or determine the particle size or concentration.

[0117] In some embodiments, the controller 110 is further configured to determine the amount of particles 210 in the form of droplets per unit volume of the fluid 208 based on the droplet rate and the droplet size. The controller 110 may also be configured to determine the particle size based on the amplitude of the pulses contained in the signal data in response to the signal not crossing the second threshold signal level. The controller 110 may further be configured to determine the particle size based on the width of the pulses contained in the signal data in response to the signal crossing the second threshold signal level. Further, the controller 110 may be configured to determine the particle size based on the particle rate.

[0118] Capacitive-based sensors

[0119] In other embodiments, a capacitance-based sensor (not shown) may be used as the particle sensor 112. To detect individual particles and assess fuel cleanliness, a capacitance sensor may be fabricated in the microfluidic channel 201 (e.g., near the outlet). The capacitance sensor may be used to detect particles 210, such as water or other droplets or metal particles. The capacitance sensor may include interdigitated electrodes to form a flat capacitor. The capacitance of this channel may be calculated by the following formula:

[0120]

[0121] Among them, ε f is the dielectric constant of the fluid in the microfluidic channel, and l, w, and a are the geometric dimensions of the electrodes. The change in capacitance when a particle passes through the microfluidic channel can be simplified to (approximately proportional to):

[0122]

[0123] Among them, ε p is the dielectric constant of the particle, and A p is the area of ​​the particle.

[0124] Capacitive sensors can be used to sense various 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 constants of various particles and fluids. Large differences in the dielectric constant of the particle material and the background fluid may produce larger signal differences. In general, in addition to the dielectric difference between the particle and the background fluid, the signal may also be related to the particle size. In the case where the size is known (or approximately known) (this can be done by using a particle separation element 302 (see Figures 9 and 10 ) to determine), the signal can be used to determine the dielectric constant difference, as well as possible contaminant materials.

[0125]

[0126]

[0127] Table 1

[0128] Figure 7 2 is a conceptual diagram showing one example of an arrangement 220 using a particle sensor 112 in conjunction with a microfluidic channel 221. The microfluidic channel 221 may include an inlet 222 and an outlet 224 having at least a first flow branch 226 and a second flow branch 228.

[0129] A flow of fluid 208 and particles 210 in the flow of fluid may be received at an inlet 222. A particle sensor 112 positioned along the microfluidic channel 221 may detect any particles 210 to provide signal data representative of signals corresponding to the fluid 208 and the particles 210 dispersed therein. The controller 110 may be operably coupled to the particle sensor 112 to receive an indication that a particle 210 has been detected.

[0130] The controller 110 can be operably 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 the fluid flow to one branch or the other. The controller 110 can be configured to control the flow routing element to direct the fluid flow to the first flow branch 226, for example, until the particle sensor 112 in the microfluidic channel 221 detects a threshold level of particles 210. The controller 110 can also be configured to determine whether a threshold level of particles 210 is present in the microfluidic channel 221 based on signal data from the particle sensor 112. In response to determining that a threshold level of particles 210 is present in the microfluidic channel 221, the controller 110 can control the flow routing element 230 to direct the fluid flow to the second flow branch 228.

[0131] The threshold level of particles 210 may be determined in any suitable manner. Non-limiting examples include detecting one or more particles above a threshold size, detecting a number of particles exceeding a threshold number, detecting a threshold rate (or frequency) of particles, or detecting a threshold concentration of particles in a fluid.

[0132] Controller 110 can also determine the flow rate of fluid 208 in microfluidic channel 221. The flow rate can be used to determine the appropriate time to control fluid routing element 230 to direct fluid to second flow branch 228 and the duration of controlling fluid routing element to direct fluid back to first flow branch 226.

[0133] The flow path selection element 230 may include one, two or more valves 232, solenoids, or any other suitable mechanism for diverting the flow of the fluid 208. In some embodiments (not shown), the flow path selection element 230 includes two valves 232, each valve being positioned along one of the flow branches 226, 228. The valves 232 may be alternately opened or closed to allow the fluid 208 to flow through the first flow branch 226 or the second flow branch 228.

[0134] Water drop removal

[0135] In some embodiments, arrangement 220 can be described as a droplet removal system or a microfluidic droplet diverter system that can be used to remove water droplets (such as particles 210) from hydrocarbon fluids. The diverter system can include a microfluidic droplet diverter, or a flow route selection element 230, and a particle sensor 112 (e.g., an optical type or a capacitive type) that can detect individual water droplets in a microfluidic channel 221. In the case where the microfluidic channel 221 contains water droplets, the fluid can be diverted to a waste stream, such as a second flow branch 228, via a valve switch or other mechanism (such as valve 232). The waste stream can be transferred to a waste collection area, transferred to a water removal filter (such as a barrier or coalescing filter), or returned to the main fuel tank. The time of fluid diversion can be determined based on the geometry of the microfluidic channel (such as the size and length between the sensor and the diverter valve) and the flow rate. After the water droplets are transferred to the waste stream, the diverter valve can be switched so that the fluid is transferred to the main outlet, such as the first flow branch 226. The main outlet is considered clean (ie, fuel without water droplets) and may be routed to a particulate removal filter, a high pressure common rail system, or other parts of the fuel system.

[0136] In another configuration, the microfluidic droplet diverter can include two valves. One valve can be in the main outlet channel, such as the first flow branch 226, and the other valve can be in the waste outlet channel or the second flow branch 228. The valve can be close to the junction where the inlet flow channel, the waste outlet channel and the main outlet channel meet, and thus incorporated into the microfluidic device. Alternatively, the valve can be away from the junction and independent of the microfluidic device (for example, in a tube or pipeline leaving the device). When the water drop sensor detects a water drop, the main outlet valve can be closed, and the waste outlet valve can be opened.

[0137] The flow splitter system may include more than one microfluidic channel to increase the total throughput. Multiple channels may or may not share the same particle sensor 112. Channels containing water droplets may be detected by the sensor output specific to that channel (see FIG. 11A to FIG. 11B ).

[0138] The flow splitter system can also be used with a fuel system with two parallel coalescing elements. When a water sensor positioned downstream of the first coalescing element detects water, one or more valves can switch the flow from the first coalescing element to the second coalescing element. This can allow the driver to change the filter at longer intervals or at a more convenient time.

[0139] Figure 8It is a conceptual diagram showing another example of an arrangement 240 of a particle sensor 112 using a microfluidic channel 241 in conjunction with a hydroseparator 260, which can be described as a microfluidic separation channel. The microfluidic channel 241 may include an inlet 242 and an outlet 244, the outlet having at least a first flow branch 246 and a second flow branch 248. As shown, the microfluidic channel 241 of the hydroseparator 260 is curved. The curve can follow a circular shape. In other embodiments, the microfluidic channel 241 can be curved and have multiple S-shaped shapes. Any suitable curved shape can be used to provide sufficient inertial force, so as to concentrate particles within a specific size range at a specific flow rate. The inlet 242 can be positioned at one end or end region, and the outlet 244 can be positioned at the opposite end or end region.

[0140] The hydrodynamic separator 260 can be designed such that at a predetermined flow rate of the fluid 208, the microfluidic channel 241 is configured to direct any particles 210 exceeding a corresponding threshold size into the second flow branch 248, and to direct any remaining particles into the first flow branch 246 and the second flow branch 248 of the outlet 224.

[0141] A flow of fluid 208 and particles 210 in the flow of fluid may be received at an inlet 242. A particle sensor 112 positioned along the microfluidic channel 241 may detect any particles 210 to provide signal data representing signals corresponding to the fluid 208 and the particles 210 dispersed in the fluid. The controller 110 ( Figure 1 ) may be operably coupled to particle sensor 112 to receive an indication that particle 210 has been detected.

[0142] The controller 110 may be operably coupled to a fluid pump 114 ( Figure 1 ). The fluid pump 114 can be configured to direct the fluid through the microfluidic channels 241 of the one or more hydrodynamic separators 260. The controller 110 can be configured to control the fluid pump to direct the fluid from the inlet 242 through the hydrodynamic separation element to the outlet 244. The controller 110 can also be configured to determine whether there is a threshold level of particles 210 in the microfluidic channel 241 based on the signal data from the particle sensor 112. In response to determining that there is a threshold level of particles 210 in the microfluidic channel 241, the controller 110 can control the fluid pump 114 to direct the fluid through the microfluidic channels of the hydrodynamic separator 260 at a predetermined flow rate of the fluid 208 to concentrate any particles exceeding the corresponding threshold size to the second flow branch 248.

[0143] The particle sensors 112a,b may be positioned at any suitable location along the microfluidic channel 241. In some embodiments, the particle sensors 112a,b may be positioned between the inlet 242 and the outlet 244. In some embodiments, the particle sensor 112a may be positioned closer to the inlet 242. Closer to the inlet 242, particles 210 above the threshold size may not be concentrated along the inner wall 262 of the hydroseparator 260. The particle sensor 112a may define a sensing area (schematically shown in solid lines) that covers most or all of the width of the microfluidic channel 241 from the inner wall 262 to the outer wall 264. Closer to the outlet 244, particles 210 above the threshold size may be concentrated along the inner wall 262 of the hydroseparator 260. The particle sensor 112b positioned toward the outlet 244 may define a sensing area (schematically shown in solid lines) that covers some or less than half of the width of the microfluidic channel 241 from the inner wall 262 to the outer wall 264.

[0144] Typically, when droplets are sensed, the arrangement 240 can change the fluid flow to focus the droplets into a waste stream. The flow rate can be calibrated based on size information from the particle sensors 112a, b to remove droplets or particles of a specific size. The flow rate can be changed by a pressure pulse, a depression, or a change in the flow path (such as opening or changing the valve position of one or more valves located at the outlet 244).

[0145] In some embodiments, the waste stream (such as the second flow branch 248) can be only a fraction of the size of the overall flow stream. This can minimize the impact on the overall flow stream when removing droplets.

[0146] Figures 9 and 10 300 is a conceptual diagram showing another arrangement 300 for using the particle sensor 112 with a particle separation element 302 and a microfluidic sensing element 116. The arrangement 300 can be used to sort the particles 210 and count the number of particles in different size ranges. Although the two-stage separation element 302 is shown as separating the particles into three size ranges, any suitable number (n) of stages can be used to separate the particles into different size ranges (n+1 size ranges).

[0147] In the illustrated embodiment, the particle separation element 302 is configured to sort the particles 210 in the first size range, the second size range, and the third size range into a first outlet stream 304 (containing particles in the first size range, the second size range, and the third size range), a second outlet stream 306 (containing particles in the second size range and the third size range), and a third outlet stream 308 (containing particles in the third size range) for sensing by the microfluidic sensing element 116. The particle sensor 112 can be positioned along the microfluidic sensing element 116 to detect the number of particles in each outlet stream 304, 306, 308. The controller 110 ( Figure 1 ) The number of particles associated with each size range can be determined based on the volume fraction associated with the flow branch of the particle separation element 302.

[0148] from Fig.10 As can be seen in FIG. 1 , the particle separation element 302 may include at least a first hydroseparator 320 and a second hydroseparator 322. Each hydroseparator 320, 322 may define a curved microfluidic channel to separate particles of varying sizes, which may be described as a microfluidic separation channel. The outlet of the first hydroseparator 320 may include a first flow branch 326 and a second flow branch 328. The outlet of the second hydroseparator 322 may include a first flow branch 330 and a second flow branch 332.

[0149] The second flow branch 328 of the first hydroseparator 320 can be configured to provide the first outlet stream 304. The second flow branch 332 of the second hydroseparator 322 can be configured to provide the second outlet stream 306. The first flow branch 330 of the second hydroseparator 322 can be configured to provide the third outlet stream 308. The first flow branch 326 of the first hydroseparator 320 can be in fluid communication or fluidly coupled with an inlet of the second hydroseparator 322 to provide the fourth fluid stream 310.

[0150] The first hydroseparator 320 can be configured to concentrate all particles within a first size range into the second flow branch 328. The first size range can include any particles exceeding a first threshold size. Any remaining particles not exceeding the first threshold size can be provided to the first flow branch 326 and the second flow branch 328. The remaining particles can be considered to be uniformly distributed. The ratio of the remaining particles provided to each branch 326, 328 can be determined based on the volume fraction associated with each branch 326, 328. Generally, the first flow branch 326 can receive a first portion and the second flow branch 328 can receive a second portion of any remaining particles not exceeding the first threshold size. Fig. 9As can be seen in FIG. 3 , the first outlet flow 304 from the second branch 328 includes particles within a variety of size ranges. None of the other outlet flows 306 , 308 contain particles exceeding a first threshold size.

[0151] The second hydrodynamic separator 322 can receive a flow from the first branch 326 that includes a second portion of any remaining particles that do not exceed a first threshold size. The second hydrodynamic separator 322 can be configured to concentrate all particles in a second size range into a second flow branch 332. The second size range can include any particles that exceed a second threshold size. Any remaining particles that do not exceed the second threshold size can be provided to the first flow branch 330 and the second flow branch 332, which can be only particles within a third size range. The remaining particles can be considered to be uniformly distributed. The ratio of the remaining particles provided to each branch 330, 332 can be determined based on the volume fraction associated with each branch 330, 332. Generally, the first flow branch 330 can receive the first portion and the second flow branch 332 can receive the second portion of any remaining particles that do not exceed the second threshold size. From Fig. 9 As can be seen in FIG. 3 , the second outlet flow 306 includes particles in both particle size ranges that do not exceed the first threshold size, and the third outlet flow 308 includes only particles that do not exceed the second threshold size.

[0152] The microfluidic sensing element 116 can be in fluid communication with the particle separation element 302. The microfluidic sensing element 116 can include a plurality of microfluidic channels 340, which can be described as microfluidic sensing channels, each microfluidic channel being in fluid communication with a different flow branch of the particle separation element 302. The microfluidic channels 340 can be arranged in parallel. In particular, each microfluidic channel 340 receives a different outlet flow 304, 306, 308. The particle sensor 112 can be positioned and configured to detect the number of particles flowing through each microfluidic channel 340.

[0153] The controller 110 can determine the 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 channel 340. For the purpose of illustration, 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 threshold size) is evenly divided between the two branches, the number of particles in each outlet stream can be calculated as follows:

[0154]

[0155] Among them, n 1 is the first size range, n 2 is the second size range, n 3is the third size range, d 1 is the first threshold size, d 2 is the second threshold size, c 1 is the number of particles counted in the first outlet flow 304, c 2 is the number of particles counted in the second outlet stream 306, and c 3 is the number of particles counted in the third outlet flow 308 .

[0156] Generally, the inlet of the particle separation element 302 can receive the randomly distributed particles 210. The particle separation element 302 can sort the particles 210 into different outlet streams 304, 306, 308. The outlet streams 304, 306, 308 can be received by the microfluidic sensing element 116. The particle sensor 112 can count the number of particles in each microfluidic channel 340 of the microfluidic sensing element 116 and determine the number of particles in each size range.

[0157] In some embodiments, particle sensor 112 may include a detector aligned with each microfluidic channel 340 to count the number of particles in each channel. In other embodiments, particle sensor 112 may use a shared detector across multiple channels to count the number of particles in each channel.

[0158] Arrangement 300 can be described as a microfluidic particle sensor, which can be used to measure the fluid cleanliness level in liquid applications. In one example, the microfluidic particle sensor can be used in a diesel filter system to measure fluid cleanliness. The sensor can be placed upstream, downstream, or as a bypass of the filter. The sensor can include a segmented level or particle separation element 302, which, for example, divides particles into flow lines based on ISO cleanliness codes, which can include particles of 4 to 6 microns in the first flow, 6 to 14 microns in the second flow, and particles greater than 14 microns in the third flow. Particles less than 4 microns in size can be excluded from calculation, or additional levels (equal to four levels) can be added to capture particles less than 4 microns, 4 to 6 microns, 6 to 14 microns, and particles greater than 14 microns. The microfluidic particle sensor can also be used for hydraulic or lubricating oil applications.

[0159] The sensor can be described as having two stages. The first stage can be described as a "separation stage" that concentrates particles into specific streamlines based on particle size, such as particle separation element 302. The second stage can be described as a "sensing stage" that includes multiple sensing channels (such as microfluidic sensing element 116), where streamlines containing specific particles are transmitted to different channels. Each channel has a particle sensor or particle counter. The design of the separation stage can determine the range of particle sizes that enter each channel. By counting or otherwise detecting particles in the sensing channels, the particle size distribution can be determined.

[0160] Once the particles have been concentrated into streamlines based on their particle size, these streamlines can be transmitted to different sensing channels (such as microfluidic channels 340). Each sensing channel corresponds to a particle size range (based on the design and performance of the separation stage). Each sensing channel can be associated with a particle sensor. The particle sensor can detect the passage of particles in the sensing channel or count them. The particle sensor can be optical (using light absorption, fluorescence, scattering or other optical methods), electronic (using capacitive sensors or impedance sensors) or magnetic. When the signal output of each channel is unique, the sensing channels can share a single particle sensor.

[0161] This microfluidic particle sensor using a passive particle concentration scheme upstream of a particle counter may not need to be calibrated when counting particles. This may allow for simplified manufacturing. Microfluidic particle sensors may also be designed to work on a series of different types of particles with different properties (such as electronic properties or magnetic properties). Microfluidic particle sensors may also count individual particles one by one, rather than reading bulk fluids, which may increase sensitivity. Using microfluidic channels may also minimize the effects of background fluids or carrier fluids.

[0162] FIG. 11A to FIG. 11B is a conceptual diagram showing an example of a technique for using, for example, a light detector 206 ( Figure 6 ) and the like share a light detector to count the number of particles in the plurality of microfluidic channels 340a, 340b, 340c. The hole element 350 may be similar to the hole element 218 ( Figure 6 ), except that the hole element 350 includes a plurality of holes 204 aligned with each microfluidic channel 340a, 340b, 340c. Each set of holes 204 can define a unique spacing pattern along the corresponding microfluidic sensing channel 340a, 340b, 340c. The unique spacing pattern can also be described as a unique orifice pattern.

[0163] Controller 110 (see Figure 6) can be configured to determine signal data based on the signal from the light detector 206, and determine whether a particle has passed through the sensing area 216 based on the signal data. The controller 110 can determine a unique spacing pattern associated with particles passing through the sensing area 216 based on the signal data. In particular, particles passing through the microfluidic sensing channel 340a can provide first unique signal data 342a, particles passing through the microfluidic sensing channel 340b can provide second unique signal data 342b, and particles passing through the microfluidic sensing channel 340c can provide third unique signal data 342c. The signal processing or pattern recognition processing of the controller 110 can be configured to distinguish these unique patterns to identify the corresponding microfluidic sensing channels 340a, 340b, 340c and the number of particles in the corresponding microfluidic sensing channels.

[0164] Typically, a unique spacing pattern provides a different time profile for a droplet to move through a specific microfluidic sensing channel 340a, 340b, 340c. In the illustrated embodiment, a series of holes are placed at different distances from each other so that a droplet moving through the channel will give several signal dips, and the time pattern of the dips is specific to the channel. Orifice patterns that produce different signal profiles (such as orifice openings of different shapes) can also be used to create a unique signal. Unique spacing and unique shapes can also be used together. If there are multiple droplets in a channel, a signal deconvolution algorithm can be used to distinguish between the individual channels.

[0165] In some embodiments, a diffraction grating may also be used to control the light entering the channel. A diffraction grating may be in or enclosed in a channel and direct the light path toward a specific detector in a detector array.

[0166] Although the present disclosure is not limited thereto, an understanding of various aspects of the present disclosure will be gained through the discussion of specific examples and illustrative embodiments provided below, which provide particle separation to supplement or replace filters. Various modifications of the examples and illustrative embodiments, as well as additional embodiments of the present disclosure will be apparent herein.

[0167] Fig.12 360 is a conceptual diagram illustrating one example of a fluid system 360 that may be used to remove particles using a particle separation element 102. A particle separation element 102, which may include a hydrodynamic separator element, may be used on the fluid system 360 along a main flow line 362.

[0168] As shown, 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 primary outlet flow using a first flow branch 363 and a secondary outlet flow using a second flow branch 364. The first flow branch 363 and the second flow branch 364 can be recombined along the main flow line 362 upstream of the fluid destination 106, which can include the rest of the system 360.

[0169] The secondary outlet flow may be provided to a filter 366 along the second flow branch 364 upstream of recombination with the primary outlet flow. An optional filter 368 may be positioned, for example, along the first flow branch 363 upstream of recombination or along the main flow line 362 downstream of recombination.

[0170] The particle separation element 102 may 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.

[0171] The particle separation element 102 may be configured to remove particles having a diameter greater than a certain threshold size from the main flow line 362 while the fluid pump 114 provides fluid at a certain flow rate.

[0172] Separator element 102 can be used to concentrate particles higher than a specific threshold size into a part of total fluid flow. The particle flow of aggregation can be concentrated or directed to the secondary outlet flow along the second branch 364, and the secondary outlet flow can be provided to a filter 366, which can be described as a dead end filter to remove particles. After passing through the filter 366, the fluid of the particle flow of the aggregation of the second flow branch 364 can be combined with the remaining fluid from the first flow branch 363, and is transported to the rest of the system (shown as fluid destination 106). The particles higher than the critical size can be mostly removed from the overall fluid provided to the fluid destination 106.

[0173] In system 360, only a portion of the total fluid flow is filtered through filter 366. In some embodiments, the aggregated particle flow provided to 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, the flow rate in a system that does not use particle separation element 102. The lower flow rate may result in lower filter pressure drop and / or longer filter life, or both lower filter pressure drop and longer filter life.

[0174] Additional filters 368 may be used to remove particles below a critical size, for example, along a "clean flow" line along the first flow branch 363 after the fluid flow lines are combined, or along the main flow line 362. A flow meter or variable pressure object in the clean flow along the first flow branch 363 may be used to properly balance the flow between the two flows exiting the separator element 102.

[0175] The technique of coupling the separator element 102 to the filter can be used in a variety of applications, such as engine fuel, engine oil, engine hydraulic system, and stationary hydraulic system. This technique may be particularly useful in engine oil, engine hydraulic system, or stationary hydraulic system where the fluid is recirculated through the filter system.

[0176] Example

[0177] Equipment Manufacturing

[0178] In Example 1, a hydroseparator was fabricated as a microfluidic device from polydimethylsiloxane (PDMS) using standard soft lithography techniques. Briefly, a photomask was prepared using DraftSight and printed at 20,000 dpi (CAD / Art Services, Inc.; Brandon, OR). A SU-8 mold was prepared using SU-8 2100 photoresist (MicroChem; Newton, MA). Process parameters are described in the SU-8 2100 data sheet provided by MicroChem. PDMS (Sylguard 184; Dow Corning; 10:1 w / w base: curing agent) was poured onto the mold, degassed for 30 minutes, and cured in an oven at 85°C overnight. After the PDMS was removed from the wafer, inlet and outlet holes were punched with a biopsy needle. Particles and fibers in the PDMS were removed using scotch tape. 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.

[0179] Particle imaging

[0180] In Example 2, fluorescent particles were suspended in deionized water for testing (Table 1). Particles of 2, 10, and 20 micrometers (μm) were provided as aqueous suspensions. These samples were diluted and tested directly.

[0181] The 25 μm and 30 μm particles are provided in powder form. These samples were prepared by adding sodium dodecyl sulfate surfactant (SDS) to deionized water to prepare the test solutions.

[0182] A typical mixture contained 50 mg of particles, 100 mg of SDS and 500 mL of deionized water. The particle size distribution was determined using a laser diffraction particle size analyzer (Beckman-Coulter LS-320).

[0183] The particles were fed into the hydroseparator prepared according to Example 1 using a pressure-driven flow system (ElveFlow OB1-Mk3; Elvesys, Paris, France). The system contained an online flow meter for real-time flow measurement (Elveflow FS4 (0-1 mL / min) or FS5 (0.2-5 mL / min); Elvesys; Paris, France). The flow rate can be controlled by pressure or flow in the ESI software package.

[0184] Particle concentration within the hydrodynamic separator was measured optically using an Olympus IX-73 inverted microscope (Olympus Life Science; Waltham, MA, USA) in conjunction with a mercury vapor short arc lamp (U-HGLGPS, Olympus Life Science; Waltham, MA, USA). Fluorescence filter cubes were selected to match the absorption and emission properties of the fluorescent particles. Images were taken with a 10x objective. Images were acquired using MicroManager (Version 1.4; https: / / micro-manager.org / wiki / Micro-Manager ) Images were captured using a Prime BSI sCMOS camera (Teledyne Photometrics; Tuscany, AZ).

[0185]

[0186] Table 2: Fluorescent particle characteristics

[0187] Prior to particle injection, each hydroseparator was pressure-flow calibrated using deionized (DI) water to correct for unreliable flow meter readings for particle-containing solutions. The data were fit to a second-order polynomial and used to determine the operating pressure for the desired experimental flow rate.

[0188] During the particle experiment, the system pressure was controlled and the pressure-flow data was recorded. If the pressure-flow data showed decay over the experimental time frame, it was assumed that the particles were collected somewhere in the apparatus and the data was not recorded.

[0189] After the experiment, the devices were cut in half, and the channel depths were measured optically on a Keyence VHX digital microscope (Keyence; Itasca, IL).

[0190] Once the pressure-flow relationship of the device is calibrated, experiments can be performed with a single fluorescent particle solution at a constant Dean number or flow rate. Fluorescence images are taken at different angles through the device to measure particle concentration as a function of length (L = αR c , where α is the radian angle through the device and R is the radius of curvature measured at the inner wall). These angles are around e.g. Fig.14 Each hydroseparator shown is defined by a circular shape. Fig.14 is a conceptual diagram showing the relative positions of angles around the hydroseparator 400 at inlet 10° (A), 180° (B), 270° (C), and outlet 350° (D). The cMOS camera integration time is set to maximize the signal difference without saturating any pixel.

[0191] Image analysis in ImageJ open source software was used to determine the extent of particle concentration. The pixel intensity of the channel was measured at each imaging position of the device. The pixel intensity was assumed to be proportional to the average particle concentration. The locations where the particles were concentrated were determined based on the export images (340° or 350°). For each image, the concentration percentage was determined as the ratio of the integrated pixel intensity of the concentrated area to the integrated pixel intensity of the entire channel as follows:

[0192]

[0193] Fig.13A A representative image from the device entrance 380 at 10 degrees is shown. Fig. 13B A representative image from device outlet 382 at 350 degrees is shown. Fig. 13C is across Fig.13A Graph 390 of pixel intensity of the channel labeled by line 384 versus channel position (in pixels). Fig.13D is across Fig. 13B A graph 392 of the pixel intensity of the channel versus the channel position (in pixels) is shown, marked by line 386 in FIG. Boxes 394 , 396 are considered to be concentrated areas.

[0194] Focused study: Same equipment, different Dean numbers (140μm depth: 25μm particles)

[0195] In Example 3, particles of 25 μm were concentrated in a hydrodynamic separator with a Dean number of two (channel width: 500 μm, channel depth: 140 μm, radius of curvature: 20 mm). Fig.15A graph 410 of percent concentration versus channel length data is shown at a pressure of 1010 mbar (3.97 mL / min) for a Dean number of 15. Graph 410 shows three distinct regions: an initial region 412 where particles are not concentrated, a region 414 where particles are concentrated, and a region 416 where particles are fully concentrated.

[0196] At the device inlet, the concentration of particles is about 35%. There is no increase in concentration over the first 14 mm of the channel length, which may be due to shear lift forces causing particles to migrate from the center of the channel to the edge of the channel. This region 412 of the device can be described as a particle migration region and has a length L 0 This length may depend on particle size, fluid properties and flow rate.

[0197] After the particle migration region, the percentage of concentrated particles can increase linearly with respect to the channel length. This region 414 of the device can be described as the linear concentration region. The slope of the linear fit can be described as the linear concentration ratio (r f ). The percentage of concentrated particles increases generally linearly until it reaches a maximum value.

[0198] Once the maximum particle concentration is reached, the particle concentration may remain approximately constant. This region 416 of the device may be described as a fully concentrated region. In this example, the maximum concentration percentage (f m ) is shown to be about 90% (ie, 90% of the particles are concentrated).

[0199] The length of the hydroseparator that can be used to achieve the target concentration percentage can be described as:

[0200]

[0201] Among them, L D is the length of the hydroseparator channel required to achieve the target concentration percentage, L 0 is the length of the particle migration region, r f is the linear concentration ratio, f 0 is the particle concentration percentage at the inlet (and during the particle migration region 414), and f t is the target concentration percentage. 0 <f t <f m This equation can be used specifically when .

[0202] Table 3 shows the data of focusing experiments performed with the same equipment at different Dean numbers. The length of the particle migration zone and the length required to achieve 90% focusing are similar and almost identical.

[0203]

[0204] Table 3: Aggregate data from experiments with the same equipment but different Dean numbers

[0205] Experiments using the same Dean number but different equipment (104μm depth: 30μm particles)

[0206] In Example 4, an experiment similar to Example 3 was conducted using approximately the same Dean number but on devices with two different radii of curvature. 30 μm particles were used. The experimental results are shown in Table 4. For the device with a smaller radius of curvature, the length of the particle migration zone is shorter. In addition, for the device with a smaller radius of curvature, the linear concentration ratio is higher. Based on these results, for example, the length required to concentrate the particles to 50% is shorter for the device with a smaller radius of curvature.

[0207]

[0208] Table 4: Aggregate data from experiments using the same Dean number but different equipment

[0209] Generally, a device with a smaller radius of curvature can achieve a target Dean number at a lower flow rate than a device with a larger radius of curvature. When comparing the pressure drop required to concentrate particles, a smaller radius of curvature may result in a shorter channel and a lower flow rate, which may have a greater impact on the pressure drop.

[0210] As an example, based on the data in Table 4 and the applied experimental pressure, the pressure drop associated with a hydrodynamic separator designed to concentrate 50% of the particles is calculated by the following equation:

[0211]

[0212] Among them, P app is the pressure applied by the experiment, L D is the length required to achieve 50% concentration (Table 4), R c is the radius of curvature of the device (Table 4), and the term An experimental device design is illustrated in which the device covers only 350° of the arc length to allow for the inlet and outlet ports. The calculated pressure drops are shown in Table 4. Devices with smaller radii of curvature were used to focus particles at much lower pressure drops.

[0213] Length of the linear concentration region

[0214] It has recently been discovered that the length of the linear concentration region required to achieve maximum particle concentration (85%-95% particle concentration) can be described by the following relationship:

[0215]

[0216] Where Re is the Reynolds number, De is the Dean number, and D H is the hydraulic diameter of the hydroseparator, w is the channel width, and R c is the radius of curvature of the hydroseparator. More specifically, the relationship is as follows:

[0217]

[0218] Furthermore, for a specific particle size, the length of the linear concentration region required to achieve maximum particle concentration can be described by the following relationship:

[0219]

[0220] Where a is the particle diameter. The particle diameter can be the equivalent spherical diameter of a particle with a sphericity greater than 0.5. For particles with a diameter greater than 8% of the channel hydraulic diameter and less than or equal to 50% of the channel height, this equation can predict the length of the linear concentration region.

[0221] The overall length of the hydroseparator can be determined or calculated as:

[0222] L D =L 0 +L f (Equation 13)

[0223] This equation can be used to calculate the minimum hydroseparator channel length required to achieve maximum particle concentration for various applications. Experimental results show that the particle migration area L 0 The length range is the hydraulic separator L required to achieve maximum particle concentration D 0% to 29% of the total length. Further, the data show that the particle migration area L 0 The length range is the linear concentration area L f 0% to 40% of the length. Thus, the length of the hydroseparator channel L D Can be greater than or equal to the linear concentration region length L f length to achieve maximum particle concentration. Hydroseparator channel length L D Can be compared to the linear concentration area L f The length of the channel is no greater than 40% to achieve particle concentration balanced with minimizing pressure drop across the channel.

[0224] Illustrative Embodiments

[0225] Some embodiments relate to a hydroseparator.

[0226] In embodiment A1, a system includes:

[0227] A hydrodynamic separation element comprising one or more hydrodynamic separators, each hydrodynamic separator defining a fluidically connected tortuous microfluidic channel, each microfluidic channel defining:

[0228] an inlet configured to receive a fluid and particles dispersed in the fluid, wherein the particles have a different composition than the fluid, and

[0229] an outlet including a first flow branch and a second flow branch,

[0230] wherein, at a predetermined flow rate, each microfluidic channel is configured to direct any particles exceeding a corresponding threshold size into the second flow branch, and to direct any remaining particles into the first flow branch and the second flow branch;

[0231] a particle sensor positioned along the one or more hydrodynamic separators, the particle sensor configured to provide signal data representative of signals corresponding to the fluid and particles in the fluid; and

[0232] a controller operably coupled to the particle sensor to receive signal data and operably coupled to a fluid pump in fluid communication with the hydraulic separation element, the controller being configured to:

[0233] Control the fluid pump to direct the fluid through the hydraulic separation element,

[0234] determining whether a threshold level of particles is present in the at least one microfluidic channel based on signal data from the particle sensor, and

[0235] In response to determining that a threshold level of particles are present in at least one microfluidic channel, flow through the hydroseparation element is controlled to direct fluid through the hydroseparation element at a predetermined flow rate to concentrate any particles exceeding the corresponding threshold size into a second flow branch of the at least one microfluidic channel.

[0236] In embodiment A2, a system includes the system according to embodiment A1, wherein the particle sensor includes:

[0237] a light source configured to direct a light beam of a frequency band along a path through the at least one hydrodynamic separator, wherein the frequency band is selected such that the particles have a more different absorbance than the fluid;

[0238] an aperture element defining a light aperture positioned in a path of a light beam from the light source; and

[0239] A light detector is positioned to receive the light beam in a sensing area after the light beam passes through the at least one hydroseparator and the light hole, the light detector being configured to provide signal data representative of an amount of light of the frequency band remaining after passing through the at least one hydroseparator.

[0240] In embodiment A3, a system includes the system of embodiment A1, wherein the particle sensor includes a capacitive sensor.

[0241] In embodiment A4, a system includes a system according to any of the preceding A embodiments, the system further comprising a source reservoir in fluid communication with the inlet and the second flow branch, wherein fluid and particles can be pumped from the source reservoir to the hydraulic separation element and selectively returned to the source reservoir through the second flow branch.

[0242] Some embodiments relate to a particle splitter.

[0243] In embodiment B1, a system includes:

[0244] A particle separation element, the particle separation element comprising:

[0245] One or more microfluidic channels in parallel fluid communication, each microfluidic channel defining:

[0246] an inlet configured to receive a fluid and particles dispersed in the fluid, wherein the particles have a different composition than the fluid, and

[0247] an outlet including a first flow branch and a second flow branch;

[0248] a flow routing element positioned along at least one flow branch of at least one outlet;

[0249] a particle sensor positioned along one or more microfluidic channels, the particle sensor configured to provide signal data representative of a signal corresponding to a fluid and particles dispersed in the fluid; and

[0250] a controller operably coupled to the at least one flow routing element and operably coupled to the particle sensor to receive signal data, the controller being configured to:

[0251] controlling the flow route selection element to direct the fluid flow to a first flow branch of at least one outlet of the at least one microfluidic channel,

[0252] determining whether a threshold level of particles is present in the at least one microfluidic channel based on signal data from the particle sensor, and

[0253] In response to determining that the threshold level of particles is present in the at least one microfluidic channel, the flow routing element is controlled to direct the fluid flow to a second flow branch of the at least one microfluidic channel.

[0254] In embodiment B2, a system includes the system according to embodiment B1, wherein the particle separation element includes a hydraulic separator element, the hydraulic separator element includes one or more hydraulic separators, the one or more hydraulic separators include one or more microfluidic channels, wherein each microfluidic channel is curved.

[0255] In embodiment B3, a system includes the system according to embodiment B1 or B2, wherein the particle sensor includes:

[0256] a light source configured to direct a light beam of a frequency band along a path through at least one microfluidic channel, wherein the frequency band is selected such that the particles have a more different absorbance than the fluid;

[0257] an aperture element defining a light aperture positioned in a path of a light beam from the light source; and

[0258] A light detector is positioned to receive the light beam in a sensing region after the light beam passes through the at least one microfluidic channel and the light hole, the light detector being configured to provide signal data representing an amount of light of the frequency band remaining after passing through the at least one microfluidic channel.

[0259] In embodiment B4, a system includes the system of embodiment B1 or B2, wherein the particle sensor includes a capacitive sensor.

[0260] In embodiment B5, a system includes a system according to any of the preceding B embodiments, the system further comprising a source reservoir in fluid communication with the inlet and the second flow branch, wherein fluid and particles can be pumped from the source reservoir to the hydraulic separation element and selectively returned to the source reservoir through the second flow branch.

[0261] Some embodiments relate to a particle sorter.

[0262] In embodiment C1, a system comprises:

[0263] A hydrodynamic separation element comprising a plurality of hydrodynamic separators in serial fluid communication, the plurality of hydrodynamic separators comprising at least a first hydrodynamic separator and a second hydrodynamic separator, each hydrodynamic separator defining a tortuous microfluidic separation channel to separate particles of different size ranges, each microfluidic separation channel defining:

[0264] an inlet configured to receive a fluid containing particles, and

[0265] an outlet including a first flow branch and a second flow branch,

[0266] wherein, at a particular flow rate, each microfluidic separation channel is configured to direct any particles exceeding a corresponding threshold size into the second flow branch, and direct any remaining particles into the first flow branch and the second flow branch, wherein the first flow branch of the first hydrodynamic separator is in fluid communication with an inlet of the second hydrodynamic separator; and

[0267] A microfluidic sensing element, the microfluidic sensing element is in fluid communication with the hydraulic separation element, the microfluidic sensing element comprises a plurality of microfluidic sensing channels, each microfluidic sensing channel is in fluid communication with a different flow branch of the hydraulic separation element, wherein the plurality of microfluidic sensing channels comprises at least:

[0268] a first microfluidic sensing channel in fluid communication with the second flow branch of the first hydrodynamic separator to receive any particles exceeding a first threshold size, and

[0269] A second microfluidic sensing channel is in fluid communication with the second flow branch of the second hydrodynamic separator to receive any particles exceeding a second threshold size, wherein the first threshold size is greater than the second threshold size.

[0270] In embodiment C2, a system includes the system of embodiment C1, wherein the plurality of microfluidic separation channels includes a third hydrodynamic separator in fluid communication with the first flow branch of the second hydrodynamic separator.

[0271] In embodiment C3, a system comprises the system according to embodiment C1 or C2, further comprising:

[0272] a particle sensor positioned along the plurality of microfluidic sensing channels, the particle sensor configured to provide signal data representative of a signal corresponding to a particle in the fluid; and

[0273] A controller is operably coupled to the particle sensor to receive the signal data, the controller being configured to determine a number of particles associated with each size range based on the volume fraction associated with the flow branch based on the signal data.

[0274] In embodiment C4, a system includes a system according to embodiment C3, wherein at least one microfluidic separation channel includes an outlet including a first outlet branch and a second outlet branch, and further includes at least one flow route selection element positioned along the outlet of at least one microfluidic sensing channel, wherein the controller is operably connected to the at least one flow route selection element and is further configured to control the flow route selection element to direct the fluid flow to the second outlet branch in response to detecting particles in the corresponding microfluidic sensing channel.

[0275] In embodiment C5, a system includes the system of embodiment C3 or C4, wherein the particle sensor includes a capacitive sensor.

[0276] In embodiment C6, a system includes the system according to embodiment C3 or C4, wherein the particle sensor includes:

[0277] a light source configured to direct a light beam of a frequency band along a path through at least one microfluidic sensing channel, wherein the frequency band is selected such that the particles have a more different absorbance than the fluid;

[0278] an aperture element defining a light aperture positioned in a path of a light beam from the light source; and

[0279] A light detector is positioned to receive the light beam in the sensing region after the light beam passes through the light hole and at least one microfluidic sensing channel, and the light detector is configured to provide signal data representing the amount of light of the frequency band remaining after passing through the at least one microfluidic sensing channel.

[0280] In embodiment C7, a system includes a system according to embodiment C6, wherein the aperture element includes a plurality of light holes, the plurality of light holes including light holes positioned on a path of a light beam from a light source, wherein the plurality of light holes includes a different set of light holes aligned with each microfluidic sensing channel, wherein each set of light holes defines a unique spacing pattern along the corresponding microfluidic sensing channel, and wherein the light detector is positioned to receive the light beam in a sensing area after the light beam passes through the plurality of light holes and the plurality of microfluidic sensing channels, and wherein the controller is configured to determine the number of particles associated with each size range based on the unique spacing pattern.

[0281] Some embodiments relate to orifice modes.

[0282] In embodiment D1, a system includes:

[0283] a plurality of microfluidic sensing channels, each microfluidic sensing channel configured to receive a fluid flow and particles dispersed in the fluid, wherein the particles have a different composition than the fluid;

[0284] a light source configured to direct a light beam of a frequency band along a path through the plurality of microfluidic sensing channels, wherein the frequency band is selected such that the particles have different absorbances than the fluid;

[0285] an aperture element defining a plurality of light apertures, the plurality of light apertures comprising a different set of light apertures aligned with each microfluidic sensing channel, wherein each set of light apertures defines a unique spacing pattern along the corresponding microfluidic sensing channel;

[0286] a light detector positioned to receive the light beam in a sensing region after the light beam passes through the plurality of light apertures of the aperture element and through the plurality of microfluidic sensing channels, the light detector being configured to provide a signal representing an amount of light of the frequency band remaining after passing through the plurality of microfluidic sensing channels; and

[0287] a controller operably coupled to the light detector and configured to:

[0288] determining signal data based on the signal from the light detector,

[0289] determining whether a particle has passed through the sensing region based on the signal data, and

[0290] A unique spacing pattern associated with particles traversing the sensing region is determined based on the signal data.

[0291] In embodiment D2, a system includes the system of embodiment D1, wherein each microfluidic sensing 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.

[0292] In embodiment D3, a system includes the system according to embodiment D1 or D2, the system further includes a hydrodynamic separation element, the hydrodynamic separation element is positioned upstream of the plurality of microfluidic sensing channels, the hydrodynamic separation element includes a plurality of hydrodynamic separators in serial fluid communication, the plurality of hydrodynamic separators include at least a first hydrodynamic separator and a second hydrodynamic separator, each hydrodynamic separator defines a tortuous microfluidic separation channel to separate particles of different size ranges, each microfluidic separation channel defines:

[0293] an inlet configured to receive a fluid and particles dispersed in the fluid, and

[0294] an outlet including a first flow branch and a second flow branch,

[0295] Wherein, at a specific flow rate, each microfluidic separation channel is configured to direct any particles exceeding a corresponding threshold size into the second flow branch and to direct any remaining particles into the first flow branch and 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.

[0296] In embodiment D4, a system includes the system of embodiment D3, wherein the controller is further configured to determine a number of particles associated with each size range based on a volume fraction associated with the flow branch based on the signal data.

[0297] In embodiment D5, a system includes the system of embodiment D3 or D4, wherein the controller is operably coupled to a fluid pump in fluid communication with the hydraulic separation element, the controller being configured to control the fluid pump to direct fluid through the hydraulic separation element at a specific flow rate.

[0298] In embodiment D6, a system includes a system according to any one of embodiments D3 to D5, wherein at least one microfluidic sensing channel includes an outlet including a first outlet branch and a second outlet branch, and further includes at least one flow route selection element positioned along the outlet of at least one microfluidic sensing channel, wherein the controller is operably connected to the at least one flow route selection element and is further configured to control the flow route selection element to direct the fluid flow to the second outlet branch in response to detecting particles in the corresponding microfluidic sensing channel.

[0299] Some embodiments relate to water droplet detection.

[0300] In embodiment El, a system comprises the system of any A embodiment, any B embodiment, any of embodiments C4-C8, or any D embodiment, wherein the particles comprise a second fluid different from the fluid.

[0301] In embodiment E2, a system includes the system of embodiment E1, wherein the controller is further configured to determine an amount of the second fluid in the form of droplets per unit volume of the fluid based on the signal data.

[0302] In embodiment E3, a system includes the system of embodiment E2, wherein the amount does not include a second fluid dissolved in the fluid.

[0303] In embodiment E4, a system includes the system according to any preceding E embodiment, wherein the controller is configured to determine a droplet velocity or a droplet size of one or more droplets of the second fluid dispersed in the fluid flow based on the signal data.

[0304] In embodiment E5, a system includes the system of embodiment E4, wherein the controller is configured to determine the droplet rate or the droplet size based on at least one of:

[0305] The pulse amplitude contained in the signal data,

[0306] The pulse width contained in the signal data,

[0307] a first threshold signal level for detecting a minimum size droplet in the sensing area,

[0308] a second threshold signal level for detecting a droplet filling the sensing area, and

[0309] Threshold signal level crossing rate.

[0310] In embodiment E6, a system includes the system according to embodiment E5, wherein the controller is further configured to determine at least one of the following:

[0311] determining an amount of the second fluid in droplet form per unit volume of the fluid based on the droplet rate and the droplet size;

[0312] determining the droplet size based on a magnitude of a pulse contained within the signal data in response to the signal not crossing the second threshold signal level;

[0313] determining the droplet size based on a width of a pulse contained in the signal data in response to the signal crossing the second threshold signal level; and

[0314] The droplet size is determined based on the droplet velocity.

[0315] In embodiment E7, a system includes the system according to any preceding E embodiment, wherein the fluid includes a hydrocarbon fluid and the second fluid includes water.

[0316] Some embodiments relate to an engine fuel system.

[0317] In embodiment F1, a system comprises:

[0318] a fuel line configured to deliver fuel to a fuel injector system;

[0319] A hydrodynamic separation element, the hydrodynamic separation element comprising one or more hydrodynamic separators, each hydrodynamic separator defining a tortuous microfluidic channel to separate particles in a fuel, each microfluidic channel defining:

[0320] an inlet in fluid communication with the fuel line for receiving fuel, and

[0321] An outlet includes a first flow branch in fluid communication with the fuel line to provide fuel to the fuel injector system, and a second flow branch to receive particles within a specific size range.

[0322] In embodiment F2, a system includes the system of embodiment F1, wherein the particles include water droplets dispersed in a fuel.

[0323] In embodiment F3, a system includes the system of embodiment F1 or F2, further including a fuel tank in fluid communication with each inlet and in fluid communication with each second flow branch.

[0324] In embodiment F4, a system includes the system according to any preceding F embodiment, the system further comprising a fuel filter configured to filter particulates from gasoline or diesel fuel positioned along the fuel line.

[0325] In embodiment F5, a system includes a system according to any of the preceding F embodiments, the system further including a fuel pump in fluid communication with the fuel line, wherein the fuel pump is configured to provide a fuel flow along the fuel line to a fuel injector system, wherein the fuel injector system includes a high pressure common rail.

[0326] Some embodiments relate to bulk fuel systems.

[0327] In embodiment G1, a system includes:

[0328] a fuel line configured to deliver fuel from the bulk fuel storage tank to the vehicle fuel tank;

[0329] A hydrodynamic separation element, the hydrodynamic separation element comprising one or more hydrodynamic separators, each hydrodynamic separator defining a tortuous microfluidic channel to separate particles in a fuel, each microfluidic channel defining:

[0330] an inlet in fluid communication with the fuel line for receiving fuel, and

[0331] An outlet includes a first flow branch in fluid communication with a fuel line to provide fuel to a vehicle fuel tank, and a second flow branch to receive particles of a specific size range.

[0332] In embodiment G2, a system includes the system of embodiment G1, further including a bulk fuel storage tank storing fuel, the bulk fuel storage tank being in fluid communication with the inlet and optionally with the second flow branch.

[0333] In embodiment G3, a system includes the system of embodiment G1 or G2, further comprising a secondary storage tank storing fuel in fluid communication with the second flow branch.

[0334] In embodiment G4, a system includes the system according to any of the preceding G embodiments, the system further comprising a fuel filter configured to filter particulates from gasoline or diesel fuel positioned along a fuel line.

[0335] In embodiment G5, a system includes the system according to any of the preceding G embodiments, the system further comprising a fuel pump in fluid communication with the fuel line, wherein the fuel pump is configured to provide a fuel flow along the fuel line to a fuel vehicle fuel tank.

[0336] Some embodiments relate to a hydraulic particulate filter.

[0337] In embodiment H1, a system includes:

[0338] a hydraulic fluid line configured to deliver hydraulic fluid from the hydraulic pump to the hydraulic component;

[0339] A hydraulic separation element comprising one or more hydraulic separators, each hydraulic separator defining a tortuous microfluidic channel for separating particles in a hydraulic fluid, each microfluidic channel defining:

[0340] an inlet in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump, and

[0341] An outlet includes a first flow branch in fluid communication with a hydraulic fluid line to provide hydraulic fluid to a hydraulic component, and a second flow branch to receive particles within a specific size range.

[0342] In embodiment H2, a system includes the system according to embodiment H1, further including a hydraulic fluid filter for filtering particles from the hydraulic fluid, the hydraulic fluid filter being positioned along a hydraulic fluid return line fluidically connected between a second flow branch and a hydraulic fluid reservoir, the hydraulic fluid reservoir being in fluid communication with an inlet of a hydraulic pump.

[0343] Some embodiments relate to enhanced hydraulic degassing.

[0344] In embodiment I1, a system includes:

[0345] a hydraulic fluid return line configured to deliver hydraulic fluid from the hydraulic component to a hydraulic pump;

[0346] A hydraulic separation element comprising one or more hydraulic separators, each hydraulic separator defining a tortuous microfluidic channel for separating particles in a hydraulic fluid, each microfluidic channel defining:

[0347] an inlet in fluid communication with the hydraulic fluid line to receive hydraulic fluid from the hydraulic pump, and

[0348] An outlet includes a first flow branch in fluid communication with a hydraulic fluid line to provide hydraulic fluid to a hydraulic pump, and a second flow branch to receive particles within a specific size range.

[0349] In embodiment I2, a system includes the system according to embodiment I1, wherein the particles include gas bubbles.

[0350] In embodiment I3, a system includes the system according to embodiment I2, further comprising a nucleation filter for nucleating bubbles in a hydraulic fluid in fluid communication between the hydraulic component and the inlet.

[0351] In embodiment I4, a system includes the system according to embodiment I3, further comprising:

[0352] a main reservoir in fluid communication between the first flow branch and the hydraulic pump; and

[0353] A sedimentation reservoir is in fluid communication between the second flow branch and the main reservoir.

[0354] Thus, various embodiments of systems and methods for separating particles in hydrocarbon fluids are disclosed. Although reference is made herein to the accompanying drawings that form a part of the present disclosure, at least one of ordinary skill in the art will appreciate that many different adaptations and modifications of the embodiments described herein are within the scope of the present disclosure or do not depart from the scope of the present disclosure. For example, aspects of the embodiments described herein may be combined with one another in a variety of ways. Therefore, it should be understood that within the scope of the appended claims, the claimed invention may be practiced in other ways than those expressly described herein.

[0355] All references and publications cited herein are expressly incorporated by reference in their entirety for all purposes except to the extent they are in any way directly inconsistent with the present disclosure.

[0356] Unless otherwise specified, all scientific and technical terms used herein have the meaning commonly used in the art. The definitions provided herein are to aid in the understanding of certain terms frequently used herein and are not meant to limit the scope of the present disclosure.

[0357] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims may be understood as modified by the terms “exactly” or “approximately.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and the appended claims are approximations that may vary, for example, within typical experimental error depending upon the desired properties sought to be obtained by one skilled in the art utilizing the teachings disclosed herein.

[0358] The recitation of numerical ranges by endpoints includes all numbers subsumed within 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. As used herein, the term "up to" or "not greater than" a number (e.g., up to 50) includes that number (e.g., 50), and the term "not less than" a number (e.g., not less than 5) includes that number (e.g., 5).

[0359] Orientation-related terms, such as "upstream" and "downstream," are used to describe the relative positions of components and are not meant to limit the absolute orientation of the contemplated embodiments.

[0360] The term "coupled" or "connected" refers to elements being directly attached to each other (in direct contact with each other) or indirectly attached (with one or more elements between and attaching the two elements). Either term may be modified with "operably" and "operably," which are used interchangeably to describe a connection or connection that is configured to allow the components to interact to perform a function.

[0361] As used herein, the term "configured to" may be used interchangeably with the terms "adapted to" or "structured to," unless the context of the present disclosure clearly dictates otherwise.

[0362] The term "or" is generally used in its inclusive sense, for example, meaning "and / or", unless the content 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.

[0363] The phrases "at least one of," "including at least one of," and "one or more of" followed by a list refer to any one of the items in the list and any combination of two or more items in the list.

Claims

1. A system comprising: A hydrodynamic separation element, the hydrodynamic separation element comprising one or more hydrodynamic separators, each hydrodynamic separator defining a fluidically connected tortuous microfluidic channel, each microfluidic channel defining: an inlet configured to receive a first fluid and particles dispersed in the first fluid, wherein the particles have a different composition than the first fluid, and an outlet, the outlet comprising a first flow branch and a second flow branch, wherein, at a predetermined flow rate, each microfluidic channel is configured to direct any particles exceeding a corresponding threshold size into the second flow branch, and to direct any remaining particles into the first flow branch and the second flow branch; a particle sensor positioned along the one or more hydrodynamic separators, the particle sensor configured to provide signal data representative of signals corresponding to the first fluid and particles in the first fluid; a controller operably coupled to the particle sensor to receive signal data and operably coupled to a fluid pump in fluid communication with the hydraulic separation element, the controller being configured to: controlling the fluid pump to direct the first fluid through the hydraulic separation element, determining whether a threshold level of particles is present in at least one microfluidic channel based on signal data from the particle sensor, and In response to determining that the threshold level of particles are present in the at least one microfluidic channel, controlling the flow through the hydroseparation element to direct the first fluid through the hydroseparation element at a predetermined flow rate to concentrate any particles exceeding the corresponding threshold size into a second flow branch of the at least one microfluidic channel; and A source reservoir is in fluid communication with the inlet and the second flow branch, wherein the first fluid and the particles are pumpable from the source reservoir to the hydraulic separation element and selectively returned to the source reservoir through the second flow branch.

2. The system according to claim 1, wherein: The particle sensor comprises: a light source configured to direct a light beam of a frequency band along a path through the at least one hydrodynamic separator, wherein the frequency band is selected such that the particles have a more different absorbance than the first fluid; an aperture element defining a light aperture positioned in a path of a light beam from the light source; and A light detector is positioned to receive the light beam in a sensing area after the light beam passes through the at least one hydroseparator and the light hole, the light detector being configured to provide signal data representative of an amount of light of the frequency band remaining after passing through the at least one hydroseparator.

3. The system according to claim 1, wherein: The particle sensor comprises a capacitive sensor.

4. The system according to any one of claims 1 to 3, wherein: The particles include a second fluid different from the first fluid.

5. The system according to claim 4, wherein: The controller is further configured to determine an amount of the second fluid in the form of droplets per unit volume of the first fluid based on the signal data.

6. The system according to claim 5, wherein: The amount does not include the second fluid dissolved in the first fluid.

7. A system according to any one of claims 4 to 6, wherein: The controller is configured to determine a droplet velocity or a droplet size of one or more droplets of a second fluid dispersed in the flow of the first fluid based on the signal data.

8. The system according to claim 7, wherein: The controller is configured to determine the droplet rate or the droplet size based on at least one of: the pulse amplitude contained in the signal data, the pulse width contained in the signal data, a first threshold signal level for detecting a minimum size droplet in the sensing area, a second threshold signal level for detecting a droplet filling the sensing area, and Threshold signal level crossing rate.

9. The system according to claim 8, wherein: The controller is further configured to determine at least one of the following: determining an amount of the second fluid in droplet form per unit volume of the first fluid based on the droplet rate and the droplet size; determining the droplet size based on a magnitude of a pulse contained within the signal data in response to the signal not crossing the second threshold signal level; determining the droplet size based on a width of a pulse contained within the signal data in response to the signal crossing the second threshold signal level; as well as The droplet size is determined based on the droplet velocity.

10. The system according to any one of claims 4 to 9, wherein: The first fluid comprises a hydrocarbon fluid and the second fluid comprises water.

11. A system comprising: A particle separation element, the particle separation element comprising: One or more microfluidic channels in parallel fluid communication, each microfluidic channel defining: an inlet configured to receive a first fluid and particles dispersed in the first fluid, wherein the particles have a different composition than the first fluid, and an outlet, the outlet comprising a first flow branch and a second flow branch; a flow routing element positioned along at least one flow branch of at least one outlet; a particle sensor positioned along one or more microfluidic channels, the particle sensor configured to provide signal data representative of signals corresponding to the first fluid and particles dispersed in the first fluid; a controller operably coupled to the flow routing element and operably coupled to the particle sensor to receive the signal data, the controller being configured to: controlling the flow route selection element to direct the fluid flow to a first flow branch of at least one outlet of the at least one microfluidic channel, determining whether a threshold level of particles is present in the at least one microfluidic channel based on signal data from the particle sensor, and In response to determining that the threshold level of particles is present in the at least one microfluidic channel, controlling the flow routing element to direct fluid flow to a second flow branch of the at least one microfluidic channel; and A source reservoir is in fluid communication with the inlet and the second flow branch, wherein the first fluid and the particles are pumpable from the source reservoir to the separation element and selectively returned to the source reservoir through the second flow branch.

12. The system according to claim 11, wherein: The particle separation element comprises a hydrodynamic separator element comprising one or more hydrodynamic separators, the one or more hydrodynamic separators comprising the one or more microfluidic channels, wherein each microfluidic channel is tortuous.

13. The system according to claim 11 or 12, wherein: The particle sensor comprises: a light source configured to direct a light beam of a frequency band along a path through the at least one microfluidic channel, wherein the frequency band is selected such that the particles have a more different absorbance than the first fluid; an aperture element defining a light aperture positioned in a path of a light beam from the light source; and A light detector positioned to receive the light beam in a sensing region after the light beam passes through the at least one microfluidic channel and the light hole, the light detector being configured to provide signal data representative of an amount of light of the frequency band remaining after passing through the at least one microfluidic channel.

14. The system according to claim 11 or 12, wherein: The particle sensor comprises a capacitive sensor.

15. A system according to any one of claims 11 to 14, wherein: The particles include a second fluid different from the first fluid.

16. The system of claim 15, wherein: The controller is further configured to determine an amount of the second fluid in the form of droplets per unit volume of the first fluid based on the signal data.

17. The system of claim 16, wherein: The amount does not include the second fluid dissolved in the first fluid.

18. A system according to any one of claims 15 to 17, wherein: The controller is configured to determine a droplet velocity or a droplet size of one or more droplets of a second fluid dispersed in the flow of the first fluid based on the signal data.

19. The system of claim 18, wherein: The controller is configured to determine the droplet rate or the droplet size based on at least one of: the pulse amplitude contained in the signal data, the pulse width contained in the signal data, a first threshold signal level for detecting a minimum size droplet in the sensing area, a second threshold signal level for detecting a droplet filling the sensing area, and Threshold signal level crossing rate.

20. The system of claim 19, wherein: The controller is further configured to determine at least one of the following: determining an amount of a second fluid in droplet form per unit volume of the first fluid based on the droplet rate and the droplet size; determining the droplet size based on a magnitude of a pulse contained within the signal data in response to the signal not crossing the second threshold signal level; determining the droplet size based on a width of a pulse contained within the signal data in response to the signal crossing the second threshold signal level; as well as The droplet size is determined based on the droplet velocity.

21. A system according to any one of claims 15 to 20, wherein: The first fluid comprises a hydrocarbon fluid and the second fluid comprises water.

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