Fractal Flow Distribution System for Monolithic Reactors
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Solution Overview
Problem
Existing fluid flow distribution systems face challenges in achieving uniform distribution of two separate flow streams with high outlet flow uniformity and packing density, particularly in applications like monolithic reactors, where traditional designs suffer from uneven flow distribution, increased pressure loss, and manufacturing complexities.
Innovation Solution
A three-dimensional nested structure of intertwined fluid transporting fractals with recursive bifurcation units, each rotated relative to the central axis, allowing for independent flow through each fractal and enabling efficient mixing of two separate fluid streams with reduced pressure loss and increased packing density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a parallel flow division scheme with manifolds is used, then the geometric and manufacturing simplicity is improved, but the flow uniformity deteriorates
Solution Approach 1:
The patent implements a nested fractal structure where smaller bifurcation units are recursively contained within larger ones, creating a hierarchical flow distribution system. This nesting approach enables complex flow control geometry to be achieved through repeated modular units, improving flow uniformity while maintaining manufacturing feasibility through pattern repetition.
Solution Approach 2:
The patent transitions from traditional two-dimensional manifold layouts to a three-dimensional fractal architecture. By utilizing vertical stacking and spatial nesting of bifurcation stages, the system achieves superior flow distribution control without proportionally increasing manufacturing complexity, as the 3D structure allows for more efficient packing and flow path optimization.
2Manufacturing precision
If a sequential fractal bifurcation approach is used, then the flow uniformity is improved, but the geometric complexity increases
Solution Approach 1:
The fractal flow distribution system is segmented into discrete, identical bifurcation units that can be independently designed and manufactured. Each unit performs a specific flow splitting function, and the overall complex geometry is achieved by assembling these standardized segments in a hierarchical pattern, reducing the complexity burden on individual manufacturing steps.
Solution Approach 2:
The patent employs periodic repetition of the fractal bifurcation pattern across multiple scales and orientations. This periodicity creates a self-similar geometric structure where the same design motif recurs throughout the system, allowing complex overall geometry to be achieved through simple repeated units rather than unique custom components at each level.
3Ease of manufacture
If perpendicular bifurcation junctions are used to satisfy manufacturing constraints, then the ease of manufacture is improved, but the pressure loss increases
Solution Approach 1:
The patent employs asymmetric bifurcation angles within each fractal unit, where the dividing channels are angled optimally to minimize flow separation and turbulence. This asymmetric design departs from simple perpendicular junctions to achieve smoother flow transitions, reducing pressure losses while remaining compatible with standard manufacturing capabilities through precise angular positioning.
Data Source
AI summary
A flow distribution system for distributing and dividing the flows of at least two separate fluids, the distribution system comprising: a three-dimensional nested structure of at least two fluid transporting fractals comprising at least a first fluid transporting fractal and a second fluid transporting fractal, each fluid transporting fractal having a respective fluid inlet which bifurcates to a plurality of fluid outlets, each fluid transporting fractal being configured to facilitate a flow therethrough independent from a flow in the other fluid transporting fractal, each fluid transporting fractal extending along and about a central axis between fluid inlet and a plurality of fluid outlets; wherein each fluid transporting fractals comprises of a series of recursive bifurcation units assembled in a selected number of stages, each bifurcation unit comprising a Y-shaped bifurcated element which is fluidly connected to two successive bifurcation units, each successive bifurcation unit being rotated relative to the central axis by an angle of between 60 and 120 degrees relative to the previous stage; each fluid transporting fractal is intertwined with the other fluid transporting fractal; each fluid transporting fractal is positioned offset from the other fluid transporting fractal about the central axis and are arranged such that each fluid outlet from one of the fluid transporting fractals is located adjoining a fluid outlet of the other fluid transporting fractal, and each fluid transporting fractal is centered about a flow axis which is laterally inclined from greater than 0 to 20 degrees from the central axis and longitudinally inclined from greater than 0 to 20 degrees from the central axis.