Angled Flow Cell Design for Dairy Process Monitoring
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Solution Overview
Problem
Existing flow cells in the dairy industry face inefficiencies due to turbulent fluid flow, air bubbles, and leakage, which affect the accuracy of chemical concentration measurements, leading to processing inefficiencies and waste.
Innovation Solution
A flow cell design featuring teardrop-shaped chambers with angled inlet and outlet passages (45° to 75° relative to the gasket plane) and a gasket with deformable material, promoting laminar flow and minimizing bubble formation, combined with an electronic measurement system for real-time data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inlet and outlet flow paths are orientated at 90° to the plane of the gasket, then the flow cell structure is simple and easy to manufacture, but turbulent flow and air bubbles are generated which reduce measurement accuracy
Solution Approach 1:
The flow paths are designed with asymmetric angles (45° to 75°) relative to the gasket plane rather than symmetric 90° orientations. This asymmetric configuration reduces turbulence and air bubble formation while maintaining manufacturing simplicity, directly resolving the contradiction between ease of manufacture and measurement precision.
Solution Approach 2:
The flow path angles are changed from the conventional 90° to a range of 45° to 75° relative to the gasket plane. This parameter modification optimizes fluid flow characteristics to eliminate turbulence and bubbles, thereby improving measurement accuracy without significantly complicating the manufacturing process.
2Productivity
If in-process monitoring is implemented using flow cells, then real-time feedback for process optimization is achieved, but air bubbles and turbulent flow reduce measurement accuracy
Solution Approach 1:
The asymmetric flow path angles (45° to 75°) create laminar flow conditions that prevent air bubble formation and turbulence, ensuring accurate real-time measurements while maintaining high productivity through continuous in-process monitoring capability.
Solution Approach 2:
The design replaces mechanical flow control mechanisms with geometric flow path optimization. The angled passages naturally guide fluid flow to achieve laminar conditions without moving parts, maintaining productivity while ensuring measurement precision.
3Device complexity
If conventional flow cells with 90° flow paths are used, then the device complexity is low, but leakage occurs leading to corrosion and limited sensor lifetime
Solution Approach 1:
The asymmetric flow path angles create favorable pressure distributions that minimize leakage risks. This geometric optimization reduces corrosion at seal interfaces and extends sensor lifetime without increasing device complexity, as the angle modification is integrated into the existing flow cell 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
The design enhances measurement accuracy, reduces maintenance, and optimizes dairy processing by minimizing waste and energy consumption through efficient in-process monitoring of chemical concentrations.
Implementation Method 1
a gasket (5) arranged to seal between the first section (2) and the second section (3). The gasket (5), the first section (2), and the second section (3) together define one or more chambers
Implementation Method 2
Each inlet passage (9) directs fluid into the respective chamber proximal the narrow end of the chamber at an angle of between about 45° to about 75° relative to the plane of gasket, and each outlet passage (10) directs fluid flow out of the wider end of the chamber at an angle between about 45° to about 75° relative to the plane of gasket
Data Source
AI summary
A flow cell with a first section and a second section, and a gasket sealing between the first and second sections. A chamber is defined in the flow cell, having a perimeter with a narrower end and a rounded wider end. An inlet passage, outlet passage, and a sensor are arranged in fluid communication with the chamber. The inlet passage directs fluid into the chamber proximal its narrow end at an angle of between about 45° and 75° relative to the plane of gasket and the outlet passage directs fluid flow out of the wider end of the chamber at an angle between about 45° and 75° relative to the plane of gasket, the inlet passage and outlet passage being angled in opposite directions. The flow cell is useful for monitoring levels of chemicals in an industrial process stream, such as lactose levels in a dairy process stream.