Fluid control devices and methods

Abstract

To suppress remaining of a fluid mixture such as debris in a fluid control device.SOLUTION: A fluid control device includes a housing, the housing has plural surfaces defining a cavity 322 within the housing. The housing includes an inlet 308A, 308B to receive a fluid mixture 310, and an outlet 314A, 314B to direct the fluid mixture out of the housing. The fluid mixture includes a fluid mixed with debris. A structure array 328 is disposed within the cavity and includes plural structures. Each of the plural structures includes a first surface coupled with an internal surface of the housing, and a second surface disposed a distance away from the internal surface of the housing. The structure array includes a first portion and a second portion. The first portion is configured to interfere with the fluid mixture to separate at least some of the debris from the fluid, and the second portion is configured to direct the fluid and at least some of the debris toward the outlet.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The subject matter described relates to fluid control devices and methods. [Background technology]

[0002] Technology Considerations The atmospheric fluid may be used in electrical and / or mechanical systems, such as to control the thermal energy of the system. For example, an electrical system may be coupled with a heat exchanger having a fluid control device, and the fluid may be directed through the heat exchanger to control the temperature of the electrical assembly. As another example, the fluid may be used in a system that may control or modify the properties of the fluid, such as a compressor. The compressor may also include a filter or filter system at the inlet of the compressor to control the movement of the fluid, such that some portions of the fluid may be directed through the compressor and other portions may not be directed through the compressor. The electrical and / or mechanical systems may be used on-board mobile systems, such as vehicles, aircraft, ships, or in stationary systems, such as wind turbines, manufacturing machines, power generation systems, and the like.

[0003] However, the fluid being directed through the system may be a mixture of fluid and some debris. For example, the debris may include particles, contaminants, dust, or other materials that may be mixed with the fluid. The fluid may be a liquid, such as water, a gas, such as air, or a liquid-gas mixture, optionally mixed with debris. However, one technical problem with fluid control devices is that at least a portion of the debris mixed with the fluid may separate from the fluid and remain within the fluid control device. As a result, over time, the amount of debris may increase, causing the fluid control device to clog and compromising the pressure of the fluid mixture moving through the device. It may also be necessary to stop operation of the electrical system to flush the device and remove the debris that has accumulated within the fluid control device. As the amount of debris that clogs within the fluid control device increases, the properties (e.g., pressure or pressure drop, velocity, flow direction, etc.) of the fluid moving through the device may be compromised, resulting in reduced efficiency of the electrical and / or mechanical systems through which the fluid is directed. Summary of the Invention

[0004] In one or more embodiments, the fluid control device includes a housing having a plurality of surfaces defining a cavity within the housing. The housing includes an inlet configured to receive a fluid mixture and an outlet configured to direct the fluid mixture out of the housing. The fluid mixture includes a fluid mixed with debris. A structural array is disposed within the cavity of the housing and includes a plurality of structures. Each of the plurality of structures includes a first surface operatively coupled to an interior surface of the housing and a second surface disposed a distance away from the interior surface of the housing. The structural array includes a first portion and a second portion. The first portion of the structural array is configured to interface with the fluid mixture to separate at least a portion of the debris from the fluid, and the second portion of the structural array is configured to direct at least a portion of the fluid and debris toward the outlet.

[0005] In one or more embodiments, the method includes directing a fluid mixture having a fluid mixed with debris through an inlet into a housing. The housing includes a plurality of surfaces defining a cavity within the housing. At least a portion of the debris is separated from the fluid as the fluid mixture moves within the first portion of the structural array with a first portion of a structural array disposed within the cavity. The structural array includes a plurality of structures, each of the plurality of structures including an interference surface, a first surface operatively coupled with an interior surface of the housing, and a second surface disposed a distance away from the interior surface of the housing. At least a portion of the fluid and debris is directed through the second portion of the structural array toward an outlet of the housing.

[0006] In one or more embodiments, a system includes a fluid control device having a housing including a plurality of surfaces defining a cavity within the housing. The housing includes an inlet configured to receive a fluid mixture and an outlet configured to direct the fluid mixture out of the housing. The inlet of the housing extends between a first end and a second end of the housing. The fluid mixture includes a fluid mixed with debris. The fluid control device includes a structural array disposed within the cavity of the housing including a first portion and a second portion. The first portion of the structural array is configured to interface with the fluid mixture to separate at least a portion of the debris from the fluid, and the second portion of the structural array is configured to direct the fluid and a portion of the debris toward the outlet. The system includes a passageway fluidly coupled to the fluid control device. The passageway extends between a passageway inlet and a passageway outlet. The passageway outlet is fluidly coupled to the inlet of the housing. The passageway outlet extends between a first end and a second end of the housing. The fluid mixture is configured to move in a first direction within the passageway, and the fluid mixture is configured to move in a second direction opposite the first direction within the cavity. [Brief description of the drawings]

[0007] The subject matter of the present invention can be understood from reading the following description of non-limiting embodiments with reference to the accompanying drawings, in which:

[0008] [Figure 1] 1 illustrates a panel assembly according to one embodiment. [Diagram 2] 2 illustrates a cross-sectional view of the panel assembly of FIG. 1; [Diagram 3] 1 illustrates a panel assembly according to one embodiment. [Figure 4] 4 illustrates a cross-sectional view of the panel assembly shown in FIG. 3. [Diagram 5] 1 illustrates a panel assembly according to one embodiment. [Figure 6] 6 illustrates a top cross-sectional view of the panel assembly shown in FIG. 5 according to one embodiment. [Figure 7] 6 illustrates a side cross-sectional view of the panel assembly shown in FIG. 5 according to one embodiment. [Figure 8] 1 illustrates a partial side view of a structure of a fluid control device according to one embodiment. [Figure 9] 1 illustrates a partial top view of a structural array of a fluid control device, according to one embodiment. [Figure 10] 1 illustrates a partial perspective view of a structural array of a fluid control device, according to one embodiment. [Figure 11] 11 illustrates a side view of the structure of the structural array shown in FIG. 10. [Figure 12] 1 illustrates a performance graph of a system, according to one embodiment. [Figure 13] 1 illustrates a performance graph of a system, according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An embodiment of the subject matter described herein relates to a system having a fluid control device and a method including directing a fluid mixture in different directions within the system. The system may also be referred to as a panel assembly including a panel operatively coupled with the fluid control device. One or more passages of the panel may direct the fluid mixture into the panel assembly and may be fluidly coupled with a housing of the fluid control device. The housing includes a plurality of surfaces defining a cavity, an inlet for receiving the fluid mixture from the one or more passages of the panel, and an outlet for directing the fluid mixture out of the housing. In one or more embodiments, the inlet of the housing may extend a width between two surfaces of the housing, and the passage may extend the same width between two surfaces of the housing. Optionally, the passage may have a width smaller or less than the width of the inlet of the housing of the fluid control device.

[0010] In one or more embodiments, the fluid control device may include a structural array disposed within the cavity, where a first portion of the structural array has a configuration (e.g., shape, size, orientation, etc.) that is different from the configuration of a second portion of the structural array. For example, the first portion may interact with the fluid mixture to separate at least a portion of the debris from the fluid of the fluid mixture, and the second portion of the structural array may direct the fluid and a portion of the debris toward an outlet of the fluid control device. The fluid mixture may exchange thermal energy with one or more other fluids and / or surfaces of the thermal system to control the temperature of the thermal system.

[0011] The structural array may include a plurality of structures. In one example, the structure may include a first surface coupled to the interior surface of the housing and a second surface disposed at a distance from the interior surface of the housing. Optionally, the structure may have alternative configurations and may be coupled to the interior surface of the housing via other orientations. The plurality of structures may include one or more interfering surfaces disposed and extending between the first and second surfaces of each structure. For example, the interfering surfaces may be angled or tilted, such that the interfering surfaces are disposed at increasing distances from the interior surface of the housing at increasing distances from the inlet of the housing. Optionally, one or more structures of the array may include two or more interfering surfaces forming a step feature.

[0012] FIG. 1 illustrates a panel assembly 100 according to one embodiment. FIG. 2 illustrates a cross-sectional view of the panel assembly of FIG. 1. In one or more embodiments, the panel assembly may be an insulated gate bipolar transistor (IGBT) inverter, or an alternative electrical assembly such as a pulse gate drive transformer, a full pulse module gate drive, a metal oxide semiconductor field effect transistor (MOSFET) such as a power MOSFET, or the like. The panel assembly may be coupled with a portable or mobile system such as a vehicle system, a rail car, an automobile, or other passenger vehicle, a mining vehicle, a bus, an aircraft (manned or unmanned such as a drone), an agricultural device, or another off-highway vehicle, a truck, a marine vehicle, or the like. Optionally, the panel assembly may be coupled with a non-vehicle alternative system such as a wind turbine, a manufacturing machine, a power generation system, a home or commercial cooling system, a personal appliance, or the like.

[0013] Panel assemblies and the XYZ coordinate system are used herein only for purposes of describing aspects of the subject matter and are not intended to limit the scope of the present disclosure. In this regard, directional indicators such as "left" and "right", "front" and "back", and "top" and "bottom" are used only to indicate the relative positions of two sides of the system along the X, Y, and Z directions, respectively.

[0014] The panel assembly includes a panel 124 and a fluid control device 102 operably coupled to the panel. In the illustrated embodiment, the fluid control device is coupled to the panel via a number of fasteners 120, but may alternatively be coupled to the panel via other coupling methods, such as welding, adhesives, or other coupling components or features. The fluid control device includes a housing 104 having a number of surfaces that define a cavity 118 within the housing. Figure 2 illustrates a cross-sectional view of the panel and the fluid control device.

[0015] In one embodiment, the fluid control device may control the amount of thermal energy transferred between the fluid control device and the panel and / or panel assembly. For example, the fluid control device may be referred to as a heat sink, a cooling device or system, etc. In one or more embodiments, the fluid control device may control the temperature of a vehicle system or other non-vehicle system. In another embodiment, the fluid control device may control the amount of transfer of another energy (e.g., mechanical, electrical, radiation, etc.) between the fluid mixture in the fluid control device and another fluid or substance in one or more components of the panel assembly. Optionally, the fluid control device may be a filter or filter system that may control which portions of the fluid mixture may be directed through the fluid control device and / or through other portions of the panel assembly, and which portions of the fluid mixture may not be directed through the fluid control device or may be directed through other portions of the panel assembly.

[0016] The panel includes inlets 108A, 108B disposed on either side of the fluid control device. The fluid mixture 110 is directed into the panel through a first inlet of the panel and passes through a passageway 122 of the panel in a first direction. In the illustrated embodiment of FIGS. 1 and 2, the passageway is disposed between a side surface of the panel and the fluid control device. For example, the passageway may direct the fluid mixture from a location outside the fluid control device and along a side of the fluid control device. The fluid mixture may be a fluid mixed with debris. The fluid may be a gas, such as air, or a liquid, such as a coolant. In one embodiment, the fluid may be atmospheric air mixed with debris or with debris mixed therein.

[0017] The fluid mixture moves within the panel passageway toward the inlet 106A, 106B of the fluid control device housing. In the illustrated embodiment, the panel passageway and the fluid control device housing are positioned such that the fluid mixture is oriented to move within the panel passageway in a first direction and within the housing cavity in a second direction that is substantially opposite to the first direction. For example, the fluid mixture rotates approximately 180 degrees before the fluid mixture is directed to the inlet of the fluid control device housing. Optionally, the first direction can be tangential to the second direction such that the fluid mixture can rotate less than or more than 180 degrees to be directed to the inlet of the fluid control device housing.

[0018] The fluid control device includes a structural array 126 disposed within the cavity of the housing. The structural array may include one or more structures that control the direction of movement of the fluid mixture. For example, the structural array may include one or more passages, channels, or other structures that may change one or more properties of the fluid mixture, such as, but not limited to, the direction of movement of the fluid mixture, the pressure, velocity, or flow rate of the fluid mixture, the amount of turbulence, the amount of the fluid mixture moving in one or more directions or toward one or more regions of the housing, the amount of energy (e.g., heat, electricity, etc.) transferred between the fluid mixture and one or more surfaces of the housing, etc. In one or more embodiments, the structural array may be fabricated of a metal alloy (e.g., aluminum, steel, copper, etc.), or a non-metallic material (e.g., a plastic material, a composite, etc.).

[0019] The fluid mixture is directed out of the housing through the outlet 114 of the fluid control device housing and out of the panel through the outlet 116 of the panel. In one or more embodiments, as the fluid mixture travels between the inlet of the housing and the outlet of the housing, some of the debris may separate from the fluid. For example, some or some of the debris may interfere with one or more surfaces of the structural array and separate from the fluid. The fluid mixture directed into the panel and into the fluid control device may have a first amount or percentage of debris mixed with the fluid, and the outlet mixture 112 directed out of the fluid control device and out of the panel may have a second amount or percentage of debris mixed with the fluid. For example, the first amount or percentage of debris mixed with the fluid to form the fluid mixture may be greater than the second amount or percentage of debris mixed with the fluid to form the outlet mixture. For example, some of the debris may remain within the fluid control device.

[0020] In one or more embodiments, the position of the fluid control device relative to the panel may be varied to control one or more flow characteristics of a fluid mixture within the fluid control device. For example, FIG. 3 illustrates a panel assembly 300 according to one embodiment, and FIG. 4 illustrates a cross-sectional view of the panel assembly of FIG. 3. The panel assembly includes a panel 324 and a fluid control device 302 operably coupled to the panel. In the illustrated embodiment, the fluid control device is coupled to the panel via a number of fasteners 326, although the fluid control device may be coupled to the panel via other coupling methods.

[0021] The fluid control device includes a housing 304 having a plurality of surfaces that define a cavity 322 within the housing. In the illustrated embodiment of FIG. 3, the housing of the fluid control device is rotated relative to the housing of the fluid control device shown in FIG. 1 and FIG. 2. Additionally, the housing of the fluid control device shown in FIG. 3 and FIG. 4 has a size larger than the size of the housing of the fluid control device shown in FIG. 1 and FIG. 2. In one embodiment, the panel assembly shown in FIG. 3 and FIG. 4 may include two of the housings of the fluid control device shown in FIG. 1 and FIG. 2. For example, the same housing of the panel assembly 100 may be used in the panel assembly 300, where the panel assembly 300 includes two housings, where the panel assembly 100 includes a single housing rotated relative to the two housings of the panel assembly 300. Alternatively, the panel assembly 300 may include a fluid control device that includes a housing unique to the housing of the fluid control device of the panel assembly 100.

[0022] The panel includes inlets 308A, 308B fluidly coupled to the first inlets 306A, 306B of the housing. The fluid mixture 310 is directed to the inlets of the panel and towards the inlets of the housing of the fluid control device. In lieu of the fluid control device shown in FIG. 2, the inlets of the housing are positioned relative to the inlets of the panel such that the fluid mixture is directed in a first direction to the panel and in the same or substantially the same first direction to the housing through the inlets. In one or more embodiments, the fluid mixture can be air mixed with or mixed with dirt. Alternatively, the fluid mixture can be an alternative gas or liquid mixed with dirt.

[0023] The fluid mixture travels within the housing towards the first outlet 314A, 314B of the housing of the fluid control device. For example, the fluid mixture may be directed in a first direction through a portion of the housing between the first inlet and the first outlet. The fluid mixture may rotate approximately 180 degrees following the fluid mixture being directed out the first outlet and before the fluid mixture is returned to the housing via the second inlet 316A, 316B of the housing. Optionally, the cavity of the housing may be configured to direct the fluid mixture in different directions such that the fluid mixture may turn or rotate a distance less than or greater than 180 degrees to be directed to the second inlet of the housing.

[0024] In one or more embodiments, the fluid control device of the panel assembly shown in Figures 3 and 4 may be referred to as a dual path fluid control device. For example, the fluid mixture may be directed at least two times through the fluid control device, such as in two different directions. For example, a dual path fluid control device may direct the fluid mixture in a first direction as a first pass through the fluid control device and in a different second direction as a second pass through the fluid control device. Alternatively, the housing of the fluid control device may have an alternative configuration such that the fluid mixture may pass through the fluid control device more than two times (e.g., three times, such as a triple pass system) or less than two times (e.g., a single pass system as shown in Figures 1 and 2).

[0025] The housing of the fluid control device includes a structural array 328 disposed within the cavity of the housing. The structural array may include a plurality of structures having uniform and / or unique shapes, sizes, orientations, etc. The structures may interact with the fluid mixture as it moves through the fluid control device to control one or more properties of the fluid mixture. For example, the structures may be positioned, arranged, oriented, sized, etc. to control one or more properties, such as, but not limited to, pressure, turbulence, flow rate or velocity, direction of movement, etc. Controlling the properties of the fluid mixture may control an amount of energy transferred between the fluid mixture and one or more surfaces of the housing. For example, the fluid mixture may transfer thermal energy to one or more surfaces of the panel assembly or other material moving through the panel assembly to control the temperature of the panel assembly.

[0026] The fluid mixture is directed out of the housing via the second outlet 320 of the housing of the fluid control device and out of the panel via the outlet 318 of the panel. In one or more embodiments, as the fluid mixture travels between the first inlet of the housing and the second outlet of the housing, some of the debris mixed in the fluid may separate from the fluid. For example, at least some of the debris may separate from the fluid when the fluid mixture interferes with a structure of the structural array. The fluid mixture directed out of the fluid control device may have an amount of debris mixed in or mixed with the fluid that is less than the amount of debris mixed in or mixed with the fluid mixture directed into the fluid control device. For example, the outlet mixture 312 directed out of the fluid control device and out of the panel may have a different amount of debris mixed in the fluid relative to the fluid mixture directed into the fluid control device. Additionally or alternatively, the outlet mixture may have one or more flow or thermal properties that are different from the flow and / or thermal properties of the fluid mixture directed into the fluid control device. For example, the outlet mixture may have an amount of thermal energy that is greater than the amount of thermal energy of the fluid mixture directed into the fluid control device. Optionally, the pressure of the outlet mixture may be different than the pressure of the fluid mixture directed into the fluid control device.

[0027] Optionally, the fluid control device may have alternative configurations. For example, FIG. 5 illustrates a panel assembly 500 according to another embodiment of the subject matter described herein. FIG. 6 illustrates a top cross-sectional view of the panel assembly, and FIG. 7 illustrates a side cross-sectional view of the panel assembly shown in FIG. 5. Similar to the panel assembly 300 shown in FIG. 3, the panel assembly 500 includes a panel 546 and a fluid control device 502. The fluid control device includes a housing 504 that is operably coupled to the panel via a number of fasteners 548. Optionally, the housing may be coupled to the panel via alternative coupling methods.

[0028] The fluid control device housing includes multiple surfaces, such as surfaces 506, 508, 510, and 512 shown in Figures 6 and 7. The surfaces define a cavity 514 of the fluid control device housing. The housing includes an inlet 524 that is fluidly coupled to an inlet 526 of the panel via a panel passageway 534. A fluid mixture 518 may be directed into the panel via the panel inlet and out of the panel passageway towards the inlet of the housing. The fluid mixture may be a fluid that is mixed with dirt or mixed with dirt. The fluid may be a gas, liquid, or a mixture of gas and liquid. In one embodiment, the fluid mixture may be atmospheric air that may be used to control temperature or thermal energy levels within the panel assembly. Alternatively, the fluid mixture may be an alternative coolant fluid.

[0029] In one or more embodiments, surface 506 may define a first end of the housing, and surface 508 may define a second end of the housing. In the illustrated embodiment, the inlet of the housing extends along a first direction between surfaces 506 and 508 (e.g., between a first end and a second end of the housing). For example, the width of the inlet is substantially the same as the width of the housing of the fluid control device. Optionally, the width of the inlet may be less or smaller than the width of the housing between surfaces 506, 508. Optionally, the inlet may be positioned such that a center or a substantial center of the inlet is aligned with a central axis (not shown) of the housing between surfaces 506, 508. Optionally, the center of the inlet may be positioned closer to surface 506 relative to surface 508. Optionally, the inlet may have any alternative location, shape, or size. In addition, the passage outlet of the panel passage extends between surface 506 (e.g., a first end of the housing) and surface 508 (e.g., a second end of the housing). For example, the width of the passageway outlet between surfaces 506, 508 may be substantially the same as the width of the housing inlet.

[0030] In one or more embodiments, the fluid control devices of the panel assemblies illustrated in Figures 5-7 may be referred to as single-pass fluid control devices, e.g., a fluid mixture may travel once through the fluid control device, as opposed to the dual-pass fluid control devices illustrated in Figures 3 and 4, in which the fluid mixture is directed through the fluid control device at least two times.

[0031] Similar to the panel assembly 100 shown in Figures 1 and 2, the fluid control device of the panel assembly 500 is positioned such that the fluid mixture may rotate approximately 180 degrees after it is directed through the panel passageway and before it is directed to the housing inlet. Optionally, the housing cavity may be configured to direct the fluid mixture in different directions such that the fluid mixture may turn or rotate less than or greater than 180 degrees to be directed to the housing inlet. The fluid mixture is directed out of the housing through the fluid control device housing outlet 528 and out of the panel through the panel outlet 530.

[0032] The fluid control device includes a structural array 516 disposed or positioned within a cavity of the housing. The structural array includes a plurality of structures 536 positioned to interfere with the fluid mixture moving within the cavity. In one or more embodiments, the structures of the structural array may form or create passages within the cavity to control the direction of movement of the fluid mixture. Optionally, the structures may be positioned, shaped, and sized to control the pressure of the fluid mixture at different locations or positions within the cavity. Optionally, the structures may be positioned, shaped, and sized to control other flow characteristics of the fluid mixture, such as, but not limited to, velocity or flow rate, turbulence, rotational forces, etc.

[0033] In one or more embodiments, as the fluid mixture travels between the first inlet of the housing and the second outlet of the housing, a portion of the debris entrained in the fluid may separate from the fluid. For example, at least a portion of the debris may separate from the fluid when the fluid mixture interferes with a structure of the structural array. The fluid mixture directed out of the fluid control device may have an amount of debris entrained or mixed in the fluid that is less than an amount of debris entrained or mixed in the fluid mixture directed into the fluid control device. For example, the outlet mixture 532 directed out of the fluid control device and out of the panel may have a different amount of debris entrained in the fluid compared to the fluid mixture directed into the fluid control device, and may have one or more flow or thermal properties that differ from the flow and / or thermal properties of the fluid mixture directed into the fluid control device, etc.

[0034] In one or more embodiments, the structural array may be separated into two or more portions. For example, the first portion 520 may be disposed or positioned proximate to an inlet of the housing, and the second portion may be disposed or positioned proximate to an outlet of the housing. For example, the second portion of the structural array is downstream of the first portion of the structural array in the direction of movement of the fluid mixture through the fluid control device. The structures of the first portion of the structural array may have a different shape, size, and / or configuration than the shape, size, and / or configuration of the second portion of the structural array. For example, the first portion of the structural array may have one or more features designed to interface with the fluid mixture, and the second portion of the structural array may have different features designed to control the movement of the fluid mixture. The first portion of the structural array may be designed to interface with the fluid mixture to separate a portion of the debris from the fluid, and the second portion of the structural array may be designed to reduce the amount of debris in the fluid (e.g., velocity, pressure, direction of movement, rotational forces, turbulence, etc.) to control the flow characteristics of the fluid mixture as the fluid mixture is directed through the second portion of the structural array toward the outlet of the housing.

[0035] 8 illustrates an example of a cross-sectional view of a first portion 520 of a structure 536 of a structural array, according to one embodiment. The structure includes a first surface 540 that is operably coupled to an interior surface 538 of the housing. In one embodiment, the first surface may be coupled to the interior surface via one or more bonding methods (e.g., welding, gluing, fastening, etc.) or the structure may be a unitary structure or formed integrally with the interior surface of the housing. For example, the structure and housing may be formed as a unitary structure by casting, printing, molding, etc.

[0036] The structure includes a first surface coupled to an interior surface of the housing and a second surface 542 disposed a distance away from the interior surface of the housing. In one embodiment, the second surface may be coupled to another interior surface of the housing. Optionally, the second surface may be disposed at a location within the cavity of the housing. Optionally, a portion of the second surface may be coupled to an interior surface of the housing (not shown) and another portion of the second surface may not be coupled to the interior surface of the housing or may be separated from the interior surface of the housing by a distance.

[0037] The structure includes an interference surface 544 extending between a first and second surface of the structure. In the illustrated embodiment, the distance between the interference surface and the interior surface of the housing increases continuously with increasing distance in the direction of movement of the fluid mixture 518 (e.g., the first direction). In addition, the interference surface is disposed at increasing distances away from the inlet of the housing. For example, the interference surface is an angled or inclined surface relative to the interior surface of the housing and extends between the first and second surfaces of the structure. Optionally, the angled, inclined, or oblique surface of the interference surface may increase in a non-continuous manner in the direction of movement of the fluid mixture. For example, the interference surface may include a step, a wave, or the like.

[0038] In one or more embodiments, the first portion of the structure including the interference surface may be shaped to control the amount of debris that may be separated from the fluid. For example, the interference surface may be shaped to increase the amount of debris that is separated from the fluid in the first portion of the structural array. The first portion of the structural array may be shaped to control the amount of debris that is mixed with the fluid that is directed to the second portion of the structural array. For example, increasing the amount of debris that is separated from the fluid in the first portion of the structural array decreases the amount of debris that is moved in the second portion of the structural array.

[0039] 9 illustrates a top view of a structural array 916 of a fluid control device, according to one embodiment. The structural array includes a first portion 920 and a second portion 922 downstream of the first portion in a direction of movement of the fluid mixture 518 within the fluid control device. The structural array includes a plurality of structures 936A, 936B. Each of the plurality of structures includes an interference surface 944A, 944B, respectively, that interferes with the fluid mixture to separate at least a portion of the debris from the fluid. The fluid mixture with a reduced amount of debris may travel through a passage or conduit defined by adjacent structures toward an outlet (not shown) of the housing.

[0040] In the illustrated embodiment, the interference surface 944A of the first structure 936A is linearly offset from the interference surface 944B of the second structure 936B. For example, the interference surface 944A of the first structure 936A is positioned at a first location (e.g., proximate to the inlet 902 of the fluid control device) and the interference surface 944B of the second structure 936B is positioned at a second location (e.g., a distance away from the inlet in the direction of movement of the fluid mixture) such that adjacent first and second structures are staggered with respect to each other. In the illustrated embodiment, each first structure is positioned adjacent to a second structure, and each first structure is linearly offset from each second structure. Optionally, the structure array may have structures arranged or positioned in an alternative pattern and / or random arrangement. Controlling the position of the interference surfaces of the different structures controls the amount of the fluid mixture that can be directed into the passage between adjacent first structures and into the passage between adjacent first and second structures. In the illustrated embodiment, the first and second structures are positioned such that the width or space between each adjacent first and second structure in the structural array is substantially the same. Optionally, one or more structures may be positioned closer to or farther away from adjacent structures such that the width or space between adjacent structures in the structural array is non-uniform.

[0041] FIG. 10 illustrates a partial perspective view of a structural array 1016 of a fluid control device, according to one embodiment. FIG. 11 illustrates a side view of a structure 1036 of the structural array shown in FIG. 10. A first portion 1004 of the structural array includes a step feature 1020. The step feature may be referred to as an angled step, beveled feature, slanted step, or the like. In the illustrated embodiment, each structure includes a first surface 1040 that is operably coupled with an inner surface 1038 of the housing. The structure also includes a second surface 1042 disposed a distance away from the inner surface of the housing. The second surface is disposed a distance away from the inner surface of the housing in a first direction 1022 and a distance away from the inlet 1002 of the fluid control device in a second direction 1024.

[0042] The structure also includes a third surface 1048 disposed between a first surface coupled to the interior surface of the housing and a second surface disposed a distance away from the interior surface. The structure includes a first interference surface 1044 extending between the first surface and the third surface, and a second interference surface 1046 extending between the third surface and the second surface. For example, the two interference surfaces form a step feature of the first portion of the structural array. In the illustrated embodiment, the interference surfaces extend radially relative to the interior surface of the housing. For example, the interference surfaces are positioned at increasing distances away from the interior surface of the housing in a first direction 1022 and increasing distances away from the inlet in a second direction 1024. Optionally, the interference surfaces may extend in a direction substantially perpendicular to the interior surface of the housing, or may extend in an alternative radial direction relative to the interior surface of the housing.

[0043] In one or more embodiments, the first portion may additionally include surfaces disposed at different distances from the interior surface and additional interfering surfaces extending therebetween to form a step feature having multiple steps. In the illustrated embodiment of FIG. 10, three structures are coupled to the interior surface of the housing, the three structures having substantially similar step features. Optionally, the structural array may include any number of structures, and one or more of the structures may have a step feature that is different or unique relative to the step feature of another structure.

[0044] The step features included in each of the structures are shaped to control the amount of debris separated from the fluid, to control the direction of movement of the fluid mixture, and / or to control different locations within the first portion where different amounts of debris are separated from the fluid, and different locations where the fluid mixture (e.g., having a reduced amount of debris mixed with the fluid) is directed toward a second portion of the structural array. For example, the fluid mixture is directed toward the first interference surface 1044. A portion of the debris is separated from the fluid in response to the fluid mixture interfering with the first interference surface. A first portion 1052A of the first reduced fluid mixture (e.g., the first reduced fluid mixture having a reduced amount of debris compared to the fluid mixture directed into the fluid control device) is directed away from the third surface of the step feature and toward a passage or conduit formed between adjacent structures of the structural array toward an interior surface of the housing. Additionally, a second portion 1052B of the first reduced fluid mixture is directed toward the second interference surface 1046.

[0045] Another portion of the debris is separated from the fluid in response to a second portion of the first reduced fluid mixture interfering with the second interfering surface to create a second reduced fluid mixture 1054. The second reduced fluid mixture has an amount of debris mixed with the fluid that is less than the amount of debris in the first reduced fluid mixture and less than the amount of debris in the fluid mixture. The second reduced fluid mixture is directed toward a passageway formed between adjacent structures of the structural array in a direction away from the second surface of the step feature and toward an interior surface of the housing. For example, debris may be collected on the first and second interfering surfaces, allowing a fluid mixed with a reduced amount of debris to move or flow between adjacent structures, through a second portion of the structural array, and toward an outlet of the fluid control device.

[0046] FIG. 12 illustrates a performance graph 1200 of a system, such as a panel assembly, according to one embodiment. The graph includes a horizontal axis 1204 representing an increasing amount of debris moving through the system and a vertical axis 1202 representing the resistance of the fluid mixture as it moves through the system. For example, the resistance may indicate a change in pressure of the fluid mixture in the system, such as a pressure drop. The performance graph illustrated in FIG. 12 may represent the performance of a fluid control device of the panel assembly illustrated in FIGS. 1 and 2. For example, the system may include a panel and a fluid control device, where the panel includes a passageway disposed between a side surface of the panel and a side surface of the fluid control device. In addition, the fluid control device may be a single-pass fluid control device. Data line 1206 illustrates increasing the resistance by increasing the amount or quantity of debris mixed with the fluid. Data point 1210 illustrates an increase in pressure drop in the fluid control device of approximately 200% after approximately 1600 grams of debris is directed into the fluid control device.

[0047] Alternatively, FIG. 13 illustrates a performance graph of another system according to one embodiment. The graph includes a horizontal axis 1204 representing the increasing amount of debris moving through the system and a vertical axis 1202 representing the resistance of the fluid mixture as it moves through the system. For example, the resistance may represent a pressure drop of the fluid mixture in the system. The graph illustrated in FIG. 13 may represent the performance of a fluid control device of the panel assembly shown in FIGS. 5-7. For example, the system may include a panel and a fluid control device, where the inlet of the fluid control device extends to a width that is substantially the same as the width of the housing of the fluid control device. In addition, the fluid mixture may move within a passageway having a width that is approximately the same as the width of the housing, such that the volume of the fluid mixture moving toward the inlet of the fluid control device is distributed (substantially evenly or unevenly) along the width of the inlet.

[0048] The graph includes a data line 1306 that indicates increasing the amount or quantity of trash increases the resistance. Data point 1310 indicates approximately 1600 grams of trash being directed into and passing through the fluid control device. Unlike the performance graph illustrated in FIG. 12, data point 1310 illustrated in FIG. 13 indicates substantially no pressure drop (e.g., minimal change in resistance) after approximately 1600 grams of trash is introduced into the fluid control device. For example, the change in resistance from zero grams of trash to approximately 1600 grams of trash is less than 0.5%. Additionally, the change in resistance from approximately zero grams to approximately 8000 grams of trash is less than 5%. For example, the fluid mixture moving through the fluid control device illustrated in FIGS. 5-7 had a reduced pressure drop compared to the fluid mixture moving through the fluid control device illustrated in FIGS. 1 and 2. In one or more embodiments, the reduced pressure drop of the fluid mixture moving within the fluid control device illustrated in Figures 5-7 may indicate a reduced amount of debris clogging within the housing as compared to the fluid control device illustrated in Figures 1 and 2.

[0049] In one or more embodiments, the fluid control device includes a housing having a plurality of surfaces defining a cavity within the housing. The housing includes an inlet configured to receive a fluid mixture and an outlet configured to direct the fluid mixture out of the housing. The fluid mixture includes a fluid mixed with debris. A structural array is disposed within the cavity of the housing and includes a plurality of structures. Each of the plurality of structures includes a first surface operatively coupled to an interior surface of the housing and a second surface disposed a distance away from the interior surface of the housing. The structural array includes a first portion and a second portion. The first portion of the structural array is configured to interface with the fluid mixture to separate at least a portion of the debris from the fluid, and the second portion of the structural array is configured to direct at least a portion of the fluid and debris toward the outlet.

[0050] Optionally, at least a portion of the fluid and debris may travel through a second portion of the structural array, between adjacent ones of the plurality of structures of the structural array, towards the outlet.

[0051] Optionally, the shape of a first portion of the structural array may differ from the shape of a second portion of the structural array.

[0052] Optionally, one or more of the plurality of structures of the structural array may include two or more interfering surfaces that form a step feature of the first portion of the structural array.

[0053] Optionally, two or more interfering surfaces forming the step feature may be operatively coupled together via a third surface of one or more of the plurality of structures.

[0054] Optionally, the third surface may be disposed between the first surface operably coupled to the inner surface of the housing and the second surface disposed a distance away from the inner surface of the housing.

[0055] Optionally, each of the plurality of structures of the structural array may include an interference surface. One or more interference surfaces of the plurality of structures may be angled relative to an interior surface of the housing.

[0056] Optionally, an interference surface of a first structure of the plurality of structures may be linearly offset from an interference surface of a second structure of the plurality of structures. The first structure may be adjacent to the second structure.

[0057] Optionally, the second portion of the structural array can be downstream of the first portion of the structural array in the direction of movement of the fluid mixture.

[0058] Optionally, the housing may be fluidly coupled to a passage configured to direct the fluid mixture towards an inlet of the housing. The passage may be configured to direct the fluid mixture to move in a first direction within the passage, and the cavity may be configured to direct the fluid mixture to move in a different second direction within the cavity.

[0059] Optionally, the inlet of the housing can be fluidly coupled to the passageway. The inlet of the housing can extend between the first and second ends of the housing, and the passageway can extend between the first and second ends of the housing.

[0060] Optionally, the housing may be operatively coupled to a vehicle system. The fluid mixture may control a temperature of the vehicle system as the fluid mixture moves within the housing.

[0061] Optionally, the housing can have a width between the first and second ends of the housing, and the inlet can extend across the same width between the first and second ends of the housing.

[0062] In one or more embodiments, the method includes directing a fluid mixture having a fluid mixed with debris through an inlet into a housing. The housing includes a plurality of surfaces defining a cavity within the housing. At least a portion of the debris is separated from the fluid as the fluid mixture moves within the first portion of the structural array with a first portion of a structural array disposed within the cavity. The structural array includes a plurality of structures, each of the plurality of structures including an interference surface, a first surface operatively coupled with an interior surface of the housing, and a second surface disposed a distance away from the interior surface of the housing. At least a portion of the fluid and debris is directed through the second portion of the structural array toward an outlet of the housing.

[0063] Optionally, the second portion of the structural array can be downstream of the first portion of the structural array in a direction of movement of the fluid mixture within the housing.

[0064] Optionally, the method may include directing the fluid mixture in a first direction within a passage fluidly coupled to the housing and directing the fluid mixture in a different second direction within the cavity.

[0065] In one or more embodiments, a system includes a fluid control device having a housing including a plurality of surfaces defining a cavity within the housing. The housing includes an inlet configured to receive a fluid mixture and an outlet configured to direct the fluid mixture out of the housing. The inlet of the housing extends between a first end and a second end of the housing. The fluid mixture includes a fluid mixed with debris. The fluid control device includes a structural array disposed within the cavity of the housing including a first portion and a second portion. The first portion of the structural array is configured to interface with the fluid mixture to separate at least a portion of the debris from the fluid, and the second portion of the structural array is configured to direct the fluid and a portion of the debris toward the outlet. The system includes a passageway fluidly coupled to the fluid control device. The passageway extends between a passageway inlet and a passageway outlet. The passageway outlet is fluidly coupled to the inlet of the housing. The passageway outlet extends between a first end and a second end of the housing. The fluid mixture is configured to move in a first direction within the passageway, and the fluid mixture is configured to move in a different second direction within the cavity.

[0066] Optionally, the structural array may include a plurality of structures, each of the plurality of structures including an interfering surface, a first surface operatively coupled to the interior surface of the housing, and a second surface disposed a distance away from the interior surface of the housing. One or more of the interfering surfaces of the plurality of structures may be angled relative to the interior surface of the housing.

[0067] Optionally, an interference surface of a first structure of the plurality of structures may be linearly offset from an interference surface of a second structure of the plurality of structures.

[0068] Optionally, one or more of the plurality of structures of the structural array may include two or more interfering surfaces that form a step feature of the first portion of the structural array. The two or more interfering surfaces that form the step feature may be operatively coupled together via a third surface of one or more of the plurality of structures. The third surface may be disposed between a first surface operatively coupled to an interior surface of the housing and a second surface disposed a distance away from the interior surface of the housing.

[0069] As used herein, the terms "processor" and "computer" and related terms, such as "processing device", "computing device", and "controller", may refer to, but are not limited to, those integrated circuits referred to in the art as computers, such as microcontrollers, microcomputers, programmable logic controllers (PLCs), field programmable gate arrays, and application specific integrated circuits, and other programmable circuits. Suitable memory may include, for example, computer-readable media. The computer-readable media may be, for example, computer-readable non-volatile media, such as random access memory (RAM), flash memory, and the like. The term "non-transitory computer-readable media" refers to tangible computer-based devices implemented for short-term and long-term storage of information, such as computer-readable instructions, data structures, program modules and sub-modules, or other data within any device. Thus, the methods described herein may be encoded as executable instructions embodied in tangible non-transitory computer-readable media, including but not limited to storage devices and / or memory devices. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. The term therefore includes tangible computer-readable media, including but not limited to non-transitory computer storage devices, including but not limited to volatile and non-volatile media, as well as removable and non-removable media such as firmware, physical and virtual storage devices, CD-ROMs, DVDs, and other digital sources such as a network or the Internet.

[0070] The singular forms "a", "an", and "the" include plural references unless the context clearly indicates otherwise. "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and the description may include cases where the event occurs and does not occur. Approximation language used herein throughout this specification and claims may be applied to modify any quantitative expression that may be permissibly varied without causing a change in the basic function involved. Thus, values ​​modified by terms such as "about", "substantially", and "approximately" or terms may not be limited to the exact value specified. In at least some cases, approximation language may correspond to the precision of an instrument for measuring the value. Throughout this specification and claims, unless the context or language indicates otherwise, range limitations may be combined and / or interchanged, and such ranges are specified and may include all subranges contained therein.

[0071] This written description uses examples to disclose embodiments, including the best mode, and enables one of ordinary skill in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The claims define the patentable scope of the disclosure, and include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that are substantially different from the literal language of the claims.

Claims

1. A fluid control device comprising a housing and a structural array, the housing includes a plurality of surfaces defining a cavity within the housing, an inlet configured to receive a fluid mixture, and an outlet configured to direct the fluid mixture out of the housing, the fluid mixture including a fluid entrained with debris; the structural array is disposed within the cavity of the housing; the structural array includes a plurality of structures, each of the plurality of structures having a first surface operatively coupled to an interior surface of the housing and a second surface disposed a distance away from the interior surface of the housing; the structural array includes a first portion and a second portion; one or more of the plurality of structures includes a third surface disposed between the first surface and the second surface and within the first portion of the array of structures; one or more of the plurality of structures includes a first interference surface extending between the first surface and the third surface in a direction away from the interior surface and the inlet, and a second interference surface extending between the third surface and the second surface in a direction away from the interior surface and the inlet, such that a step feature is formed within the first portion of the structural array; a leading edge of the second surface is linearly offset from a leading edge of the third surface, and a leading edge of the third surface is linearly offset from a leading edge of the first surface; the first interference surface of the first portion of the structural array is configured to interfere with a first portion of the fluid mixture to separate at least a portion of the debris from fluid in the first portion of the fluid mixture; the second interference surface of the first portion of the structural array is configured to interfere with a second portion of the fluid mixture to separate at least a portion of the debris from fluid in the second portion of the fluid mixture; A fluid control device, wherein the second portion of the structural array is configured to direct the fluid and at least a portion of the debris toward the outlet.

2. 2. The fluid control device of claim 1, wherein the at least a portion of the fluid and debris are configured to move through the second portion of the structural array and between adjacent ones of the plurality of structures of the structural array toward the outlet.

3. The fluid control device of claim 1 , wherein a shape of the first portion of the structural array is different from a shape of the second portion of the structural array.

4. 2. The fluid control device of claim 1, wherein each of the plurality of structures in the structural array includes the first and second interference surfaces, and the first and second interference surfaces of the plurality of structures are angled relative to the interior surface of the housing.

5. 5. The fluid control device of claim 4, wherein the first interference surface of a first structure of the plurality of structures is linearly offset from the first interference surface of a second structure of the plurality of structures, the first structure being adjacent to the second structure.

6. The fluid control device of claim 1 , wherein the second portion of the structural array is downstream of the first portion of the structural array in a direction of movement of the fluid mixture.

7. 2. The fluid control device of claim 1, wherein the housing is fluidly coupled to a passage configured to direct the fluid mixture toward the inlet of the housing, the passage configured to direct the fluid mixture to move in a first direction within the passage, and the cavity configured to direct the fluid mixture to move in a different second direction within the cavity.

8. 8. The fluid control device of claim 7, wherein the inlet of the housing is fluidly coupled to the passageway, the inlet of the housing extending between a first end and a second end of the housing, and the passageway extending between the first end and the second end of the housing.

9. The fluid control device of claim 1 , wherein the housing is operably coupled to a vehicle system and the fluid mixture is configured to control a temperature of the vehicle system as the fluid mixture moves within the housing.

10. 2. The fluid control device of claim 1, wherein the housing has a width between a first end and a second end of the housing, and the inlet extends across the same width between the first end and the second end of the housing.

11. 1. A system comprising: A fluid control device, comprising: a housing including a plurality of surfaces defining a cavity within the housing, the housing comprising an inlet configured to receive a fluid mixture and an outlet configured to direct the fluid mixture out of the housing, the inlet of the housing extending between a first end and a second end of the housing, the fluid mixture including a fluid entrained with debris; a structural array disposed within the cavity of the housing, the structural array having a first portion and a second portion, the first portion of the structural array including one or more step features having two or more interference surfaces configured to interface with the fluid mixture to separate at least a portion of the debris from the fluid, a first interference surface of the one or more step features configured to interface with a first portion of the fluid mixture and a second interference surface of the one or more step features configured to interface with a second portion of the fluid mixture, the first interference surface and the second interference surface are angled with respect to an inner surface of the housing, and the second portion of the structural array configured to direct a third portion of the fluid mixture, including the fluid and a portion of the debris, toward the outlet; a passageway fluidly coupled to the fluid control device, the passageway extending between a passageway inlet and a passageway outlet, the passageway outlet being fluidly coupled to the inlet of the housing, the passageway outlet extending between the first end and the second end of the housing; The system, wherein the fluid mixture is configured to move in a first direction within the passageway and the fluid mixture is configured to move in a different second direction within the cavity.

12. 12. The system of claim 11, wherein the structural array includes a plurality of structures, each of the plurality of structures having a first surface operably coupled to an interior surface of the housing, a second surface disposed a distance away from the interior surface of the housing, and a third surface disposed between the first and second surfaces, a leading edge of the second surface being linearly offset from a leading edge of the third surface, and a leading edge of the third surface being linearly offset from a leading edge of the first surface.

13. The system of claim 12 , wherein the first interference surface of a first structure of the plurality of structures is linearly offset from the first interference surface of a second structure of the plurality of structures.

14. The fluid control device of claim 1 , wherein the second portion of the fluid mixture has a reduced amount of debris compared to the first portion of the fluid mixture.

15. 12. The system of claim 11, wherein the second portion of the fluid mixture has a reduced amount of debris compared to the first portion of the fluid mixture, and the third portion of the fluid mixture has a reduced amount of debris compared to the second portion.

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