Modular Fluid Processing Member Segmentation
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Solution Overview
Problem
Existing fluid processing apparatuses, such as microreactors, face issues with clogging due to solid or gaseous materials produced during reactions, leading to flow path blockages, high pressure losses, and difficulties in cleaning and up-scaling, particularly due to the complexity and expense of processing members with circular ring openings.
Innovation Solution
A fluid processing apparatus comprising multiple divided components for the processing members, allowing for easier assembly and cleaning, with mirror-processed surfaces and a mechanism for relative rotation, enabling efficient fluid processing and mixing while reducing production costs through modular design and materials selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a processing member with a circular ring opening is used to achieve 1:1 mixing ratio, then mixing efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The processing member is divided into multiple segments that can be assembled together to form the complete circular ring opening. This segmentation allows each segment to be manufactured separately with standard equipment, avoiding the need for large-scale molding equipment while maintaining the efficient circular geometry for 1:1 mixing ratio
2Productivity
If a large diameter processing member is used for up-scaling, then processing capacity is improved, but production cost increases due to large-size molding and sintering equipment requirements
Solution Approach 1:
The large diameter processing member is constructed by assembling multiple smaller segments together. Each segment can be manufactured using standard-size molding and sintering equipment, avoiding the need for expensive large-scale equipment while achieving the required processing capacity through the combined area of multiple segments
Solution Approach 2:
Multiple processing members or segments are arranged in a nested or concentric configuration, allowing the system to achieve large processing capacity equivalent to a single large member while using smaller, more economically manufacturable components
3Productivity
If a processing member with openings is used to enable fluid flow, then fluid processing capability is improved, but cleaning difficulty increases when solid material clogs the flow path
Solution Approach 1:
The processing member is divided into separable segments with openings. When solid material clogs the flow path, individual segments can be removed and cleaned separately, or the clogged segment can be replaced without disassembling the entire processing member, significantly improving cleaning accessibility
Solution Approach 2:
The openings and flow paths are designed as extractable components that can be removed from the processing member. This allows direct access to internal flow paths for cleaning and maintenance, eliminating the difficulty of cleaning hidden or inaccessible channels
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 apparatus facilitates easier cleaning and up-scaling, reduces production costs, and maintains efficient fluid processing and mixing capabilities, overcoming the limitations of traditional microreactor designs by using modular components and optimized surface processing.
Implementation Method 1
a fluid pressure imparting mechanism for imparting a pressure to the fluid to be processed
Implementation Method 2
at least one of which rotates relative to the other... the fluid to be processed forms a thin film fluid
Data Source
Figure 1
Figure 2(A)~2(B)
Figure 3(A)~3(B)
AI summary
A fluid processing apparatus for processing a material to be processed between processing surfaces (1, 2) of processing members capable of approaching to and separating from each other, so as to rotate relative to each other, introduces a first fluid between the processing surfaces (1, 2), introduces a second fluid between the processing surfaces (1, 2) from another flow path (d2) independent of the first fluid, and mixes and stirs the first and second fluids between the processing surfaces (1, 2) to undergo treatment. A processing member (20) of the apparatus is composed by assembling a plurality of divided components of the processing member (20a, 20b). An opening (d20) and a flow path (d2) are formed in the space between the plurality of components of the processing member (20a, 20b). This eliminates the need to create all ring-shaped disks which are the processing member (20) as one block, and also eliminates the need to substantially process the flow path (d2) leading to the opening (d20), thereby making it possible to easily undergo decomposition and cleaning.