Integrally Formed Hollow Support for Plate Settler Flow Efficiency
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Solution Overview
Problem
Existing clarifiers face issues with support strength, corrosion, and efficiency due to welded supports, which increase fabrication time and expense, and disrupt liquid flow, making maintenance difficult and reducing efficiency.
Innovation Solution
A settler plate with a hollow support integrally formed with the plate, positioned to collect clarified liquid without projecting above the settling surface, allowing for individual channel sampling and improved flow efficiency, and formed from a single piece of metallic material without welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded supports are used to hold settler plates, then support strength is improved, but fabrication time and expense increase
Solution Approach 1:
The support and settler plate are merged into a single integrally formed component. The support is formed as an extension of the settler plate itself, eliminating the need for separate welding operations. This integration maintains structural strength while dramatically reducing fabrication time and complexity.
Solution Approach 2:
The integrally formed support serves multiple functions: it provides structural strength to hold the settler plate, acts as a flow channel for liquid, and eliminates the need for separate welding operations. This multi-functionality resolves the contradiction by combining support and flow functions in one component.
2Strength
If welded supports are used to hold settler plates, then support strength is improved, but fabrication expense increases
Solution Approach 1:
The support and settler plate are merged into a single integrally formed component manufactured in one piece. This eliminates multiple fabrication steps including welding, labor costs, and associated expenses, while maintaining the necessary structural strength through the integral design.
Solution Approach 2:
The integral support design simplifies manufacturing to such an extent that the component can be produced more economically, potentially using less expensive materials or processes, while maintaining adequate strength for the application lifecycle.
3Strength
If supports project above the settling surface, then support strength is improved, but liquid flow efficiency deteriorates due to turbulence
Solution Approach 1:
The support is designed to extend in a different dimension - downward below the settling surface rather than upward above it. This dimensional change allows the support to maintain structural strength anchored in the basin while keeping the upper surface smooth and flush with the settling surface, eliminating turbulence and improving liquid flow efficiency.
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 solution enhances support strength, reduces maintenance time, and improves flow efficiency by allowing individual channel sampling and reducing turbulence, thus increasing the overall effectiveness of the clarifier system.
Implementation Method 1
clarified liquid flowing from an individual flow channel defined by adjacent settler plates
Data Source
AI summary
The present disclosure relates to settler plates for a plate settler. The settler plates generally include a hollow support with a hollow interior to receive clarified liquid from a flow channel between adjacent settler plates. An orifice is formed through the hollow support to direct clarified liquid from the flow channel into the hollow interior. The orifice can be positioned such that clarified liquid can flow upwardly out of the flow channel and downwardly through the orifice into the hollow interior. The hollow support can be integrally formed with the settler plate. For example, the hollow support can be formed by bending a tab extending from an end of the settler plate. The tab can be bent into a hollow support with a cross section that is generally polygonal.