Thin Aperture Array With Projections For Strength
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Solution Overview
Problem
Existing aperture arrays face challenges in achieving a thin, strong structure with fine apertures due to increased production costs and complexity, and they often result in high pressure loss and decreased measurement sensitivity when used as filters or measuring devices.
Innovation Solution
A thin aperture array with a quasiperiodic or periodic structure, featuring projections that abut multiple apertures to enhance strength and a thickness of 30 μm or less, is developed, along with a production method involving overlapping patterns of apertures to create smaller apertures and maintain mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the aperture size is decreased to collect minute objects, then the collection capability is improved, but the production cost increases and production complexity increases
Solution Approach 1:
The aperture array is divided into multiple layers, with each layer containing a pattern of apertures. By stacking multiple layers with different aperture patterns, the invention achieves fine effective aperture sizes without requiring each individual aperture to be manufactured at the minimum size, thus reducing production complexity while maintaining the ability to collect minute objects
Solution Approach 2:
Multiple aperture layers are nested together in a stacked configuration, where each layer contributes to the overall filtration or measurement function. The nested structure allows the system to achieve fine effective aperture dimensions through the combination of larger apertures in different layers, avoiding the need to manufacture extremely small apertures directly
2Strength
If the aperture array thickness is increased to maintain mechanical strength, then the structural strength is improved, but the pressure loss increases and treatment efficiency decreases
Solution Approach 1:
Projections are added at specific locations within the aperture array structure, particularly at regions where mechanical strength is most needed. This localized reinforcement approach provides the necessary structural strength without increasing the overall thickness of the aperture array, thereby maintaining low pressure loss and high treatment efficiency
Solution Approach 2:
The invention transitions from a two-dimensional flat aperture array to a three-dimensional structure by adding projections that extend in the thickness direction. This dimensional change allows the structure to gain mechanical strength through vertical support elements without proportionally increasing the overall thickness, thus balancing strength requirements with pressure loss constraints
3Strength
If the aperture array thickness is increased to maintain mechanical strength, then the structural strength is improved, but the measurement sensitivity decreases
Solution Approach 1:
Projections are strategically positioned at specific locations within the aperture array to provide mechanical strength only where structurally necessary. This localized approach maintains the thin overall profile of the array, ensuring that measurement sensitivity is preserved while still achieving adequate structural support at critical points
Data Source
AI summary
A film-shaped aperture array includes a first principal surface and a second principal surface opposed to each other and a plurality of apertures penetrating the first principal surface and the second principal surface. A projection projecting from the second principal surface in a normal direction of the second principal surface is provided in at least one region in contact with three or more of the plurality of apertures in a part of the second principal surface, when viewed in plan from the normal direction of the second principal surface.