3D Gradient Porous Structure for Two-Phase Fluid Separation
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Solution Overview
Problem
Existing systems and methods for phase separation of fluids are inefficient and in need of improvement.
Innovation Solution
The development of porous, three-dimensional gradient phase separator devices fabricated via machining, powder metallurgy, and additive manufacturing techniques, featuring interconnected pores of varying sizes and shapes to separate fluid mixtures into distinct fluid phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional phase separation systems are used, then the structure is simple, but the separation efficiency is low
Solution Approach 1:
The patent employs a porous structure with interconnected pores of varying sizes to achieve efficient phase separation. The porous material provides a large surface area and multiple flow paths that enhance separation efficiency while maintaining a relatively simple overall device structure. The pore size distribution allows selective passage of different fluid phases based on capillary pressure differences.
Solution Approach 2:
The porous structure exhibits local quality variations through its gradient pore size distribution. Different regions of the porous structure have different pore sizes, creating localized zones with different separation characteristics. This gradient structure optimizes separation efficiency across the entire device while avoiding uniform complexity throughout.
2Productivity
If uniform pore size is used, then the manufacturing is simple, but the separation performance is insufficient
Solution Approach 1:
The patent utilizes parameter changes by implementing a gradient pore size distribution throughout the porous structure. The pore size varies continuously or in steps from one region to another, creating different local separation characteristics. This parameter variation enhances overall separation performance compared to uniform pore sizes, while the gradient nature provides a systematic approach to manufacturing.
Solution Approach 2:
The invention transitions from controlling pore size in one dimension (uniform size) to controlling pore size in multiple dimensions (gradient distribution through the structure). This dimensional approach to pore size control allows optimization of separation performance across different flow paths and pressure gradients, achieving superior separation without requiring extremely precise uniform pore control.
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
The devices achieve efficient separation of fluid mixtures into separate fluid phases, enabling applications such as thermal management, environmental cleanup, and industrial fluid processing with high separation efficiency and scalability.
Implementation Method 1
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
Implementation Method 2
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)
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.