Free-Form Fluid Distributor for Uniform Chromatography Flow
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Solution Overview
Problem
Existing fluid distribution systems for chromatography and solid phase synthesis columns face challenges in achieving uniform flow distribution and maintaining sanitary conditions, particularly in large-scale columns, due to issues with pressure loss, turbulence, and complex structures that are difficult to clean.
Innovation Solution
A sanitary fluid distributor unit with a channel tree structure fabricated using free form fabrication techniques, featuring smoothly curved channels and tapered segments to minimize pressure drops and avoid sharp corners, allowing for optimal design and scalability without joints or support structures, and utilizing integral filters and elastomeric sealing for improved sanitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a classical fluid distribution system with a central inlet and thin distribution channel is used, then the structure is simple to manufacture, but the flow distribution uniformity deteriorates strongly with increasing column diameter
Solution Approach 1:
The distribution channel is segmented into multiple parallel channels instead of a single thin channel. This segmentation allows each channel to maintain laminar flow conditions while collectively covering the entire column cross-section, thereby maintaining flow distribution uniformity in large-scale columns without increasing structural complexity
Solution Approach 2:
The invention transitions from a two-dimensional planar distribution channel to a three-dimensional network of parallel channels with controlled cross-sectional areas. By adjusting the cross-sectional area of each channel according to its distance from the column center, the system achieves uniform flow distribution across the entire column cross-section
2Loss of energy
If the distribution channel is made open for unrestricted lateral fluid flow, then the pressure loss is reduced, but the structural stability deteriorates
Solution Approach 1:
The distribution channels are formed as thin-walled hollow structures that provide both structural stability and fluid flow pathways. The thin walls minimize pressure loss while maintaining sufficient structural integrity to support the packed bed, eliminating the need for additional support structures that would obstruct flow
Solution Approach 2:
The distributor incorporates a porous support structure that allows unrestricted lateral fluid flow through its porous matrix. This porous structure provides both mechanical support and fluid distribution functions simultaneously, reducing pressure loss while maintaining structural stability
3Stability of the object's composition
If a filter is placed in the distribution channel to confine the inlet end of the bed, then the bed confinement is improved, but the pressure drop across the distribution channel increases
Solution Approach 1:
A porous filter structure is used instead of a solid filter. The porous structure provides bed confinement while allowing fluid to pass through with minimal pressure drop, as the pores permit lateral fluid flow that bypasses the filter resistance
4Stability of the object's composition
If support structures are incorporated in the distribution channel for structural stability, then the structural stability is improved, but the pressure loss increases due to increased tortuosity and wall friction
Solution Approach 1:
The support structure and distribution channel are merged into a single integrated thin-walled hollow structure. This eliminates the need for separate support elements that would create tortuosity and wall friction, while the thin walls of the hollow structure provide both structural stability and fluid flow pathways with minimal resistance
5Device complexity
If the distributor unit is designed as a single body by free form fabrication, then the device complexity is reduced and sanitation is improved, but the manufacturing precision requirements increase
Solution Approach 1:
Traditional mechanical manufacturing methods (machining, assembly) are replaced with free form fabrication technology. This additive manufacturing approach can directly create complex three-dimensional channel networks with precise geometries that would be difficult or impossible to achieve with conventional manufacturing, while producing a single integrated piece that eliminates assembly complexity
Data Source
AI summary
A fluid distributor unit comprising a channel system where one or more inlet channels (2) starting on an inlet side (3) of the distributor unit branch out successively into several channels (6) ending on the other side of the distributor unit, called the outlet side (4), characterised in that said distributor unit is provided in one single body (1) by free form fabrication.