3D gradient porous structure for phase separation utilizing additive manufacturing methods
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Solution Overview
Problem
Existing phase separation technologies are inefficient in separating fluid mixtures into distinct fluid phases, particularly for applications requiring precise control and scalability.
Innovation Solution
The development of porous, three-dimensional gradient porous phase separator devices that utilize interconnected pores of varying sizes to effectively separate fluid mixtures into distinct fluid phases, fabricated through machining, powder metallurgy, or additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional phase separation technologies are used, then the separation process can be performed, but the separation efficiency is insufficient and cannot achieve effective separation of fluid mixtures into distinct phases
Solution Approach 1:
The patent employs a porous structure with interconnected pores of varying sizes to enable efficient phase separation. The porous material provides a large surface area and multiple flow paths that enhance the separation of fluid mixtures into distinct liquid and gas phases, directly addressing the insufficient separation efficiency of conventional technologies
Solution Approach 2:
The patent implements a gradient porous structure where pore sizes vary spatially throughout the device. This local variation in pore quality allows different regions to perform specialized functions - smaller pores for one phase separation and larger pores for another - thereby achieving effective separation into distinct phases that uniform structures cannot accomplish
2Adaptability or versatility
If traditional phase separation devices are used, then the basic separation function is provided, but the devices lack scalability from micro-fluidics to industrial scales
Solution Approach 1:
The porous phase separator device is designed with a universal structure that can be scaled across multiple orders of magnitude from micro-fluidics to industrial applications. The same fundamental porous architecture and gradient pore size distribution principle apply regardless of scale, allowing the device to maintain functionality while adapting to different application requirements without requiring fundamentally different designs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These phase separator devices achieve efficient separation of fluid mixtures into liquid and gas phases, enabling applications in thermal management, environmental remediation, and industrial processes, with scalability from micro-fluidics to industrial scales.
Implementation Method 1
a porous structure that extends from a first end to a second end, the porous structure having an inner area having a first plurality of pores, an intermediate area having a second plurality of pores and a first outer area having a third plurality of pores; wherein the pores of the first plurality of pores are interconnected with the pores of the second plurality of pores, and the pores of the second plurality of pores are interconnected with the pores of the third plurality of pores
Data Source
AI summary
Disclosed herein are advantageous phase separator devices, and related methods of fabrication and use thereof. The present disclosure provides improved phase separator devices for phase separation of feedstreams, and improved systems/methods for utilizing and fabricating the phase separator devices. More particularly, the present disclosure provides porous (e.g., three-dimensional gradient porous) phase separator devices for phase separation of fluid mixtures (e.g., to separate a two-phase fluid mixture) to a first fluid phase flow (e.g., to a liquid flow) and to a second fluid phase flow (e.g., to a gas flow). At least a portion of the phase separator devices of the present disclosure can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques.