Integrally Formed Flow Distributor for Uniform Manifold Flow
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Solution Overview
Problem
Traditional fluid manifolds face challenges in achieving uniform flow distribution due to high velocity flows and asymmetries, often requiring additional manufacturing steps and being limited by traditional machining constraints, which can be costly and difficult to manufacture.
Innovation Solution
An integrally formed flow distributor within the fluid manifold, optimized through additive manufacturing and computational fluid dynamics (CFD) analysis, allows for complex geometries and reduced need for separate components, enhancing flow distribution by varying the size, shape, and arrangement of openings based on desired flow characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to manufacture flow distributors, then manufacturing precision can be achieved, but device complexity and manufacturing costs increase due to separate components and additional assembly steps
Solution Approach 1:
The flow distributor is merged with the manifold body through integral formation, creating a single monolithic component. This eliminates separate flow distributor parts and assembly steps while maintaining precise flow distribution control through optimized internal geometry that would be difficult to achieve with traditional machining alone.
Solution Approach 2:
The invention changes the manufacturing parameter from traditional machining to additive manufacturing, enabling complex internal geometries and optimized flow paths that cannot be achieved with conventional methods. This parameter change allows for precise flow distribution while reducing overall device complexity.
2Manufacturing precision
If traditional machining constraints are followed, then ease of manufacture is maintained, but manufacturing precision and flow distribution optimization are limited
Solution Approach 1:
The manufacturing method parameter is changed from traditional machining to additive manufacturing, which removes geometric constraints and enables complex optimized flow distributor geometries. This allows for precise flow distribution control through features that would be impossible or extremely difficult to machine traditionally.
Solution Approach 2:
The invention substitutes the mechanical machining process with additive manufacturing technology, replacing subtractive manufacturing with a layer-by-layer construction approach. This substitution enables complex internal geometries and optimized flow paths while simplifying the overall manufacturing process.
3Ease of repair
If separate flow distributor components are used, then ease of repair and replacement is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The flow distributor functionality is merged into the manifold body through integral formation. While this reduces the number of separate components and simplifies the overall device structure, the optimized internal geometry provides enhanced flow distribution control that compensates for the loss of separate component replaceability.
Data Source
AI summary
A fluid manifold includes an inlet comprising an opening into an interior of the fluid manifold, an outlet end that is positioned opposite the inlet and that is in fluid communication with the inlet, a shroud extending between the inlet and the outlet end and surrounding a flow path of the fluid manifold, and a first flow distributor positioned within the interior of the fluid manifold. The first flow distributor includes a hollow body including a first surface at a downstream side of the first flow distributor and a second surface at an upstream side of the first flow distributor, a central cavity defined by the second surface of the hollow body, and openings extending from the first surface to the second surface such that a fluid can pass from the central cavity through the openings. The first flow distributor and the fluid manifold are integrally formed.