Air Separation Module Perforated Plate Radial Support
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Solution Overview
Problem
Existing air separation modules for nitrogen generation systems in vehicles require perforations in the canister to support the separator structure, adding cost and complexity.
Innovation Solution
The air separation module employs a perforated plate with a split annulus body that snap-fits into the canister, providing radial support to the separator without the need for perforations in the canister, using a compressed and relaxed major dimension to securely attach and support the separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If perforations are added to the canister to allow oxygen-enriched fraction to exit, then the oxygen-enriched air can be properly discharged, but the canister structure becomes more complex and costly
Solution Approach 1:
The canister is segmented into functional zones: an inlet portion, an outlet portion, and a plenum portion. The plenum portion is further divided by a perforated plate into a nitrogen-enriched air collection zone and an oxygen-enriched air collection zone. This segmentation allows each zone to be optimized independently and eliminates the need for perforations in the main canister body.
Solution Approach 2:
A perforated plate is introduced as an intermediary component between the separator and the canister outlet. This plate serves as a mediator that provides radial support to the separator while allowing oxygen-enriched air to exit through its perforations, eliminating the need to perforate the canister body itself.
2Reliability
If the canister is perforated to support the separator structure, then the separator can be properly supported, but manufacturing cost and complexity increase
Solution Approach 1:
The perforated plate acts as an intermediary support structure that bears the radial load of the separator. By placing the perforations in the plate rather than the canister body, the canister maintains its structural integrity while still providing the necessary support to the separator.
Solution Approach 2:
The support function is segmented from the canister body and transferred to a separate perforated plate component. This allows the canister to be manufactured as a simple, solid structure while the perforated plate provides the necessary radial support where needed.
3Ease of manufacture
If a perforated plate with snap-fit mechanism is used, then assembly becomes simpler and cost reduces, but the plate must accommodate compressed and relaxed dimensions
Solution Approach 1:
The perforated plate is designed with a snap-fit mechanism that utilizes elastic deformation. The plate can be compressed to a smaller diameter for insertion and then springs back to its relaxed, larger diameter to secure the separator radially. This dynamic behavior simplifies assembly while accommodating dimensional variations.
Solution Approach 2:
The plate's dimensional parameters are designed to change during assembly: the major dimension is compressed during insertion and then expands to the relaxed state for final positioning. This parameter change allows the same component to serve both as an insertion tool and as a final support structure.
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
This design simplifies the fabrication and reduces the cost of air separation modules while maintaining effective separation of nitrogen and oxygen-enriched air flows, eliminating the need for perforations in the canister.
Implementation Method 1
the separator structure separates the pressurized air into a nitrogen-enriched fraction and an oxygen enriched fraction
Implementation Method 2
the perforated plate... provides radial support to the separator
Implementation Method 3
using a compressed and relaxed major dimension to securely attach and support the separator
Data Source
Figure 1
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AI summary
An air separation module includes a canister, a separator, and a perforated plate. The canister (106) has a plenum portion (128) connecting an inlet portion to an outlet portion, extends circumferentially about a canister axis, and has a plenum diameter that is larger than a canister diameter defined by the inlet and outlet portion of the canister. The separator (102) is arranged within the canister and axially spans the plenum portion to separate air received at the inlet end portion into nitrogen-enriched and oxygen-enriched air flows. The perforated plate (114) is seated within the plenum portion, fluidly couples the separator to an oxygen-enriched air outlet port defined by the plenum portion, and has a snap-fit major dimension smaller than the plenum diameter to radially support a portion of the separator axially spanning the plenum portion of the canister. Nitrogen generation systems and methods of making air separation modules are also described.