Countercurrent Contacting Device With Integral Interleaved Deflector Blades
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Solution Overview
Problem
The construction of countercurrent contacting devices with intersecting grids is time-consuming and labor-intensive due to the need for extensive welding, and existing methods to simplify this process either reduce welds by using metal casting or do not enhance the strength of the devices.
Innovation Solution
A contacting device design featuring interleaved grids of deflector blades with uncut ends and bent portions that form integral connections, eliminating the need for welding by joining adjacent blades along transverse strips and reverse bends, and incorporating apertures and directional tabs to facilitate fluid mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If individual deflector blades are welded together at crossing points to form intersecting grids, then the contacting device achieves structural strength and stability, but the construction process becomes time-consuming and labor-intensive
Solution Approach 1:
Multiple individual deflector blades are merged into a single integral blank through forming operations. The blank includes multiple deflector blades extending in different directions that are interconnected by uncut portions, eliminating the need to assemble and weld separate blades together.
Solution Approach 2:
The blank is segmented into multiple deflector blades that extend in different directions from a common uncut portion. Each blade is a distinct functional element, but they are all formed from one continuous piece of material, combining segmentation with integral construction.
2Productivity
If metal casting process is used to form subassemblies of contacting devices, then the number of welds is reduced, but the strength of the contacting device is not enhanced
Solution Approach 1:
The welding process is replaced with a forming process. The deflector blades and their interconnections are created through bending and forming operations on a blank, substituting mechanical forming for thermal welding to join components.
Solution Approach 2:
The contacting device is constructed as an integral composite structure where multiple deflector blades are combined into a single formed blank, creating a composite structural element that functions as both multiple blades and a unified strong structure.
3Reliability
If extensive welding is performed to join individual contacting elements, then the reliability and strength of the contacting device is improved, but the manufacturing complexity and labor requirements increase
Solution Approach 1:
The welding operation is extracted and eliminated from the manufacturing process. The design removes the need for joining operations by forming the complete structure with interconnections integrated into the blank itself through uncut portions.
Solution Approach 2:
The interconnections between deflector blades are prepared in advance during the forming of the blank. The uncut portions are created as integral parts of the blank formation process, so no subsequent joining action is needed to establish these connections.
Data Source
AI summary
The contacting device for countercurrent contacting of fluid streams and having a first pair of intersecting grids of spaced-apart and parallel deflector blades and a second pair of intersecting grids of spaced-apart and parallel deflector blades. The deflector blades in each one of the grids are interleaved with the deflector blades in the paired intersecting grid and may have uncut side portions that join them together along a transverse strip where the deflector blades cross each other and cut side portions that extend from the uncut side portions to the ends of the deflector blades. At least some of the deflector blades have directional tabs and associated openings to allow portions of the fluid streams to pass through the deflector blades to facilitate mixing of the fluid streams.